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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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DOE OSTI2019

Life-Cycle Approaches in Computerized Vehicle Design and Additive Technology

Computer engineering permits the creation of models closely matching actual processes and vehicle designs. Production costs may be significantly reduced, while additive technologies permit customized production, with minimal expenditure of time and materials in development and prototyping. Such technologies may expediently be used in digital design of vehicles, taking account of the complete product life cycle.

42 ENGINEERING↗

DOE OSTI2018

Tunable emergent heterostructures in a prototypical correlated metal

We report at the interface between two distinct materials, desirable properties, such as superconductivity, can be greatly enhanced1, or entirely new functionalities may emerge. Similar to in artificially engineered heterostructures, clean functional interfaces alternatively exist in electronically textured bulk materials. Electronic textures emerge spontaneously due to competing atomic-scale interactions, the control of which would enable a top-down approach for designing tunable intrinsic heterostructures. This is particularly attractive for correlated electron materials, where spontaneous heterostructures strongly affect the interplay between charge and spin degrees of freedom. Here we report high-resolution neutron spectroscopy on the prototypical strongly correlated metal CeRhIn 5 , revealing competition between magnetic frustration and easy-axis anisotropy—a well-established mechanism for generating spontaneous superstructures. Because the observed easy-axis anisotropy is field-induced and anomalously large, it can be controlled efficiently with small magnetic fields. Finally, the resulting field-controlled magnetic superstructure is closely tied to the formation of superconducting and electronic nematic textures in CeRhIn 5 , suggesting that in situ tunable heterostructures can be realized in correlated electron materials.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

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Kaylin Bugbee↗

NASA NTRSDate not supplied

TBIRD, a rapid prototyping approach for design, assembly, and test of a LEO-to-ground lasercom CubeSat

The TeraByte InfraRed Delivery (TBIRD) system is a 3U payload on a 6U CubeSat launched in May 2022 which has now demonstrated space to ground links of >1 Terabyte (TB) per pass at a max data rate of 200Gbps. As a CubeSat mission, the development of the TBIRD payload was focused on low SWaP and a “rapid prototyping” approach which accepted higher risks to accelerate the schedule and reduce costs. The optomechanical design process followed standard in-house processes to develop a system that would be robust to LEO environmental loads, with a focus on the stability of the transmit (Tx) and receive (Rx) channel performance metrics. The driving requirement of maintaining 20μrad pointing error between the TX and Rx channels forced specific attention to thermal and mechanical load changes over operational conditions, which drove major design decisions. This paper describes some of engineering challenges overcome and approaches used to make TBIRD a successful program, as well as some of the tradeoffs of rapid prototyping precision optical payloads. TBIRD successfully met and exceeded the total downlink requirements listed above, with a bandwidth of 200Gbps and a total downlink of 4.8TB of information in a single pass.

TBIRD↗

NASA NTRS2003

High-Temperature Switched-Reluctance Electric Motor

An eight-pole radial magnetic bearing has been modified into a switched-reluctance electric motor capable of operating at a speed as high as 8,000 rpm at a temperature as high as 1,000 F (=540 C). The motor (see figure) is an experimental prototype of starter-motor/generator units that have been proposed to be incorporated into advanced gas turbine engines and that could operate without need for lubrication or active cooling. The unique features of this motor are its electromagnet coils and, to some extent, its control software. Heretofore, there has been no commercial-off-the-shelf wire capable of satisfying all of the requirements for fabrication of electromagnet coils capable of operation at temperatures up to 1,000 F (=540 C). The issues addressed in the development of these electromagnet coils included thermal expansion, oxidation, pliability to small bend radii, micro-fretting, dielectric breakdown, tensile strength, potting compound, thermal conduction, and packing factor. For a test, the motor was supported, along with a rotor of 18 lb (.8-kg) mass, 3-in. (.7.6-cm) diameter, 21-in. (.53-cm) length, on bearings packed with high-temperature grease. The motor was located at the mid span of the rotor and wrapped with heaters. The motor stator was instrumented with thermocouples. At the time of reporting the information for this article, the motor had undergone 14 thermal cycles between room temperature and 1,000 F (.540 C) and had accumulated operating time >27.5 hours at 1,000 F (=540 C). The motor-controller hardware includes a personal computer equipped with analog-to-digital input and digital-to-analog output cards. The controller software is a C-language code that implements a switched-reluctance motor-control principle: that is, it causes the coils to be energized in a sequence timed to generate a rotating magnetic flux that creates a torque on a scalloped rotor. The controller can operate in an open- or closed-loop mode. In addition, the software has been modified to enable the simultaneous operation of the prototype motor or another, similar apparatus as both a motor and a magnetic bearing. Combined bearing/motor operation has been demonstrated at room temperature but had not yet been demonstrated at high temperature at the time of reporting the information for this article.

Montague, Gerald↗

DOE OSTI2023

From Atoms to Wheels: The Role of Multi-Scale Modeling in the Future of Transportation Electrification

Traditionally, prototype hardware is built for validation testing to ensure battery systems design changes meet vehicle-level requirements, which is expensive both in cost and time. Virtual engineering (VE) of battery systems for electric vehicle (EV) propulsion offers a reduced-cost alternative to the traditional development process and uses multi-scale modeling to virtually probe the impact of design changes in a particular part on the overall performance of the system. This allows for rapid iteration over multiple design spaces, without committing to build hardware. This perspective article discusses current trends in VE for EV applications and proposes improvements to accelerate EV adoption.

Garrick, Taylor R. (ORCID:0000000322518129)↗

NASA NTRS1993

New concepts for Reynolds stress transport equation modeling of inhomogeneous flows

The ability to model turbulence near solid walls and other types of boundaries is important in predicting complex engineering flows. Most turbulence modeling has concentrated either on flows which are nearly homogeneous or isotropic, or on turbulent boundary layers. Boundary layer models usually rely very heavily on the presence of mean shear and the production of turbulence due to that mean shear. Most other turbulence models are based on the assumption of quasi-homogeneity. However, there are many situations of engineering interest which do not involve large shear rates and which are not quasi-homogeneous or isotropic. Shear-free turbulent boundary layers are the prototypical example of such flows, with practical situations being separation and reattachment, bluff body flow, high free-stream turbulence, and free surface flows. Although these situations are not as common as the variants of the flat plate turbulent boundary layer, they tend to be critical factors in complex engineering situations. The models developed are intended to extend classical quasi-homogeneous models into regions of large inhomogeneity. These models do not rely on the presence of mean shear or production, but are still applicable when those additional effects are included. Although the focus is on shear-free boundary layers as tests for these models, results for standard shearing boundary layers are also shown.

Perot, J. Blair↗

NASA NTRS2020

Demonstration of Deployment Accuracy of the Starshade Inner Disk Subsystem

We present experimental results that demonstrate the required in-plane deployment accuracy of the starshade Inner Disk Subsystem (IDS). This effort was to address Milestone 7C of the Starshade Technology Activity S5, which requires that the in-plane deployment accuracy of the petal interfaces on the IDS be within +/-300um. A full-scale 10m-diameter IDS prototype was constructed. This prototype comprised a medium-fidelity perimeter truss, medium-fidelity spokes, and a low-fidelity optical shield (OS). The testbed also included gravity compensation systems and a laser tracker metrology system. The post-processed measurement uncertainties of the laser tracker were less than 30um at the 3 sigma level. Design, engineering and fabrication of these components was done by JPL, Tendeg, and Roccor. Testing was performed at the Tendeg facility in Louisville, Colorado. The IDS prototype was deployed 22 times and the locations of petal interfaces on the IDS were measured after each deployment. Based on this data, tolerance intervals were calculated that would contain 99.73% of future deployment accuracy errors with 90% confidence. These tolerance intervals are conservative estimates for 3 sigma bounds. The tolerance intervals for the three pertinent error components were found to be within the required allocations, with at least 19% margin.

Turse, Dana↗

DOE OSTI2020

Accelerating nuclear fuel development and qualification: Modeling and simulation integrated with separate-effects testing

In this work, an approach to transform and accelerate nuclear fuel development and qualification is outlined. The approach exploits advanced modeling and simulation at the outset to inform constituent and system selection and to enable integral fuel performance analyses. Analyses using these tools identify and prioritize the most important fuel performance parameters and phenomena for subsequent targeted characterization with separate-effects tests. Separate-effects testing spans out-of-pile and in-pile tests and is meant to iterate with and inform engineering-scale integral fuel performance analyses throughout the development process. Exercising this cycle in an agile fashion will increase confidence in the integral fuel performance predictions while reducing uncertainties. This process sets the stage for executing a much more limited set of well-defined integral irradiation tests designed to validate engineering-scale fuel performance codes and to confirm the performance and safety of the fuel system under prototypic conditions. This approach will reduce the time for development and qualification of a new fuel system, and it will also reduce associated costs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Activation of surface lattice oxygen in single-atom Pt/CeO 2 for low-temperature CO oxidation

To improve fuel efficiency, advanced combustion engines are being designed to minimize the amount of heat wasted in the exhaust. Hence, future generations of catalysts must perform at temperatures that are 100°C lower than current exhaust-treatment catalysts. Achieving low-temperature activity, while surviving the harsh conditions encountered at high engine loads, remains a formidable challenge. In this study, we demonstrate how atomically dispersed ionic platinum (Pt 2+ ) on ceria (CeO 2 ), which is already thermally stable, can be activated via steam treatment (at 750°C) to simultaneously achieve the goals of low-temperature carbon monoxide (CO) oxidation activity while providing outstanding hydrothermal stability. A new type of active site is created on CeO 2 in the vicinity of Pt 2+ , which provides the improved reactivity. These active sites are stable up to 800°C in oxidizing environments.

Nie, Lei (ORCID:0000000343593451)↗

DOE OSTI2023

Dual Triggered Beam Extraction Kicker (Rev. 1)

A Blumlein modulator is a relatively inexpensive pulsed power device that can deliver highly repeatable pulses that can be used to change the path of beam pulses. The modulator is primarily built with transmission line cable which is relatively inexpensive. Due to the highly repeatable nature of a Blumlein modulator it is a great tool for kicking beam pulses while producing very little spill or losses in beam current. One of the challenges with a Blumlein kicker is that the length of the kicking pulse output by the modulator is determined by the length of the cables. Cable lengths are set prior to implementation for the desired kicking pulse width. The Blumlein modulator at LANSCE uses a single thyratron which can deliver two 50-kilovolt 1,000-amp pulses of opposite polarity to kicking plates at the same time. This method makes for a very strong kick that is highly repeatable. A method that has been discussed, to deliver a different pulse width, is to add a second trigger that would be fired, once the desired pulse width has been delivered, cutting out the remaining pulse. The second trigger would offer a lot of variability with the pulse width of the kicker. This method has only ever been attempted using low current and relatively low voltages compared to the scale needed to properly kick a beam pulse. This in turn allows for the use of power supplies with a higher repetition rate. The advancement of this standard kicker technology in the accelerator facilities would attract attention within the scientific and engineering communities. The project detailed within will investigate the capabilities of different triggering topologies and design a prototype dual triggered Blumlein kicker modulator capable of variable kicking pulse width.

43 PARTICLE ACCELERATORS↗

DOE OSTI2024

Design and evaluation of a low-cost sensor node for near-background methane measurement

Abstract. We developed a low-cost methane sensing node incorporating two metal oxide (MOx) sensors (Figaro Engineering TGS2611-E00 and TGS2600), humidity and temperature sensing, data storage, and telemetry. We deployed the prototype sensor alongside a reference methane analyzer at two sites: one outdoors and one indoors. We collected data at each site for several months across a range of environmental conditions (particularly temperature and humidity) and methane levels. We explored calibration models to investigate the performance of our system and its suitability for methane background monitoring and enhancement detection, first selecting a linear regression to fit a sensor baseline response and then fitting methane response by the sensor deviation from baseline. We achieved moderate accuracy in a 2 to 10 ppm methane range compared to data from the reference analyzer (RMSE < 0.6 ppm), but we found that the sensor response varied over time, possibly as a result of changes in non-targeted gas concentrations. We suggest that this cross sensitivity may be responsible for mixed results in previous studies. We discuss the implications of our results for the use of these and similar inexpensive MOx sensors for methane monitoring in the 2 to 10 ppm range.

Furuta, Daniel↗

NASA NTRS1991

A feasibility study on the use of foil bearings in cryogenic turbopumps

The feasibility of using foil bearings in future earth-to-orbit rocket engines is studied. A design parameter of a LOX pump of the SSME was selected as a prototype for this study. It was found that three-pad journal bearings and eight-pad thrust bearings met the operating requirements of the LOX turbopump.

Heshmat, Hooshang↗

NASA NTRS1992

Computer aided systems human engineering: A hypermedia tool

The Computer Aided Systems Human Engineering (CASHE) system, Version 1.0, is a multimedia ergonomics database on CD-ROM for the Apple Macintosh II computer, being developed for use by human system designers, educators, and researchers. It will initially be available on CD-ROM and will allow users to access ergonomics data and models stored electronically as text, graphics, and audio. The CASHE CD-ROM, Version 1.0 will contain the Boff and Lincoln (1988) Engineering Data Compendium, MIL-STD-1472D and a unique, interactive simulation capability, the Perception and Performance Prototyper. Its features also include a specialized data retrieval, scaling, and analysis capability and the state of the art in information retrieval, browsing, and navigation.

Boff, Kenneth R.↗

NASA NTRS2008

Long-Term Characterization of 6H-SiC Transistor Integrated Circuit Technology Operating at 500 C

NASA has been developing very high temperature semiconductor integrated circuits for use in the hot sections of aircraft engines and for Venus exploration. This paper reports on long-term 500 C electrical operation of prototype 6H-SiC integrated circuits based on epitaxial 6H-SiC junction field effect transistors (JFETs). As of this writing, some devices have surpassed 4000 hours of continuous 500 C electrical operation in oxidizing air atmosphere with minimal change in relevant electrical parameters.

Neudeck, Philip G.↗

NASA NTRS2023

Designing Learning Experiences With A Low-Cost Robotic Arm

Robots have gained immense popularity in Hollywood and growth globally in both industrial manufacturing and non-manufacturing environments and applications such as healthcare, service sector, and space exploration. To date, there are several examples of simple and low-cost educational robotic platforms and commercially available platforms (e.g., Lego Mindstorms, VEX Robotics) for incorporation into existing curriculum. However, most low-cost examples require access to rapid-prototyping tools, such as 3D printers to manufacture the structure of the robot, while commercially available platforms are relatively expensive (> $1,000). Although the low-cost, open-source examples provide increased access, these examples require design and manufacturing tasks that would be considered outside the learning objectives of an upper-level robotics course and are better suited for other introductory courses. Thus, we asked, how can a robotic platform be incorporated into existing robotics curriculum to enhance students' learning experiences? To explore this research question, we introduce a low-cost (<$200), untethered, and transportable robotic platform that is easy to assemble using off-the-shelf components. This kit can be powered from a laptop computer and does not rely on access to rapid-prototyping tools such as 3D printers or laser cutters, making this a more accessible option in undergraduate engineering courses. Specifically, we aimed to investigate the design of experiential learning experiences for the mathematical modeling of the forward and inverse kinematics of a serial robotic arm that complements existing robotics curriculum. The experiential learning experience focuses on traditional written answer, simulation in MATLAB, and finally implementation on a robotic platform. Few studies examined this accessible option when evaluating experiential learning experiences that complement existing robotics curricula. To assess the impact of this robotic arm kit in an undergraduate course, we implemented an educational intervention that allowed us insight into student perceptions, takeaways on the course and activities involving the robotic arm, and the impact of the course on their career outlook when comparing activities that involved use of the robotic arm and those that did not. Details on the design, development and implementation of the learning activities is provided. Both quantitative and qualitative data were collected and analyzed. The results presented in this paper discuss students finding the learning activities on the robotic arms more helpful than those without, and that students found high value in the hands-on experiences and real-world scenarios offered by the activities using the robotic arm. Challenges to implementation of the robotic arms are discussed, including students’ prior knowledge of using robotic arms.

Eric J. Markvicka↗

DOE OSTI2023

NETL Direct Air Capture Center

In 2022 Congress authorized the $25M National Energy Technology Laboratory Direct Air Capture Center. The facility will be specifically targeted at accelerating the commercialization of technologies beyond the conceptual stage which have not yet reached full pilot-scale (TRL 3 to 6). The ability to operate over a wide range of conditions will help the developers to understand how their technologies respond in different climates, from summer to winter and arid to tropical. NETL recognizes that DAC technology is still early in its evolution, and a wide variety of highly varied technologies are being explored. The Center will be designed with substantial flexibility to accommodate the rapidly evolving technological landscape. Testing systems at three scales will be included: lab-scale systems designed to examine the long-term stability of DAC materials, bench-scale module testing systems capable of probing flow dynamics, and small pilot-scale skid rooms able to test prototype DAC units under a wide variety of climate conditions. The NETL DAC Center will feature dedicated engineering, technician, scientific and logistical support for experimental system design, installation, operation of experiments, and interpretation of results for projects including but not limited to kinetics of absorption/desorption, thermal duty, and post-mortem elemental characterization to understand degradation. The NETL DAC Center projects will also have access to dedicated process modeling and analysis to evaluate the technoeconomic aspects of new technologies. NETL’s Systems Engineering and Analysis (SEA) team, the Carbon Capture Simulation Initiative (CCSI), and the Institute for the Design of Advanced Energy Systems (IDAES) are all potential collaborators with NETL’s testing partners from industry, academia, and other research institutions. NETL also has world class capabilities in device scale modeling (i.e., MFIX) that will be available to help design more efficient contactors and optimize unique internal configurations that can be realized by advanced manufacturing. The talk will cover the design and capabilities of the center, the planned availability, and feedback will be solicited from the audience on DAC testing needs.

Luebke, David↗

DOE OSTI2023

Accelerating commercialization of direct air capture technology

Luebke, David↗