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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 NTRS2000

GeoSAR: A Radar Terrain Mapping System for the New Millennium

GeoSAR Geographic Synthetic Aperture Radar) is a new 3 year effort to build a unique, dual-frequency, airborne Interferometric SAR for mapping of terrain. This is being pursued via a Consortium of the Jet Propulsion Laboratory (JPL), Calgis, Inc., and the California Department of Conservation. The airborne portion of this system will operate on a Calgis Gulfstream-II aircraft outfitted with P- and X-band Interferometric SARs. The ground portions of this system will be a suite of Flight Planning Software, an IFSAR Processor and a Radar-GIS Workstation. The airborne P-band and X-band radars will be constructed by JPL with the goal of obtaining foliage penetration at the longer P-band wavelengths. The P-band and X-band radar will operate at frequencies of 350 Mhz and 9.71 Ghz with bandwidths of either 80 or 160 Mhz. The airborne radars will be complemented with airborne laser system for measuring antenna positions. Aircraft flight lines and radar operating instructions will be computed with the Flight Planning Software The ground processing will be a two-step step process. First, the raw radar data will be processed into radar images and interferometer derived Digital Elevation Models (DEMs). Second, these radar images and DEMs will be processed with a Radar GIS Workstation which performs processes such as Projection Transformations, Registration, Geometric Adjustment, Mosaicking, Merging and Database Management. JPL will construct the IFSAR Processor and Calgis, Inc. will construct the Radar GIS Workstation. The GeoSAR Project was underway in November 1996 with a goal of having the radars and laser systems fully integrated onto the Calgis Gulfstream-II aircraft in early 1999. Then, Engineering Checkout and Calibration-Characterization Flights will be conducted through November 1999. The system will be completed at the end of 1999 and ready for routine operations in the year 2000.

Thompson, Thomas↗
NASA NTRS2014

Modified ACES Portable Life Support Integration, Design, and Testing for Exploration Missions

NASA's next generation of exploration missions provide a unique challenge to designers of EVA life support equipment, especially in a fiscally-constrained environment. In order to take the next steps of manned space exploration, NASA is currently evaluating the use of the Modified ACES (MACES) suit in conjunction with the Advanced Portable Life Support System (PLSS) currently under development. This paper will detail the analysis and integration of the PLSS thermal and ventilation subsystems into the MACES pressure garment, design of prototype hardware, and hardware-in-the-loop testing during the spring 2014 timeframe. Prototype hardware was designed with a minimal impact philosophy in order to mitigate design constraints becoming levied on either the advanced PLSS or MACES subsystems. Among challenges faced by engineers were incorporation of life support thermal water systems into the pressure garment cavity, operational concept definition between vehicle/portable life support system hardware, and structural attachment mechanisms while still enabling maximum EVA efficiency from a crew member's perspective. Analysis was completed in late summer 2013 to 'bound' hardware development, with iterative analysis cycles throughout the hardware development process. The design effort will cumulate in the first ever manned integration of NASA's advanced PLSS system with a pressure garment originally intended primarily for use in a contingency survival scenario.

Kelly, Cody↗
DOE OSTI2021

Linear and Nonlinear Solvers for Simulating Multiphase Flow within Large-Scale Engineered Subsurface Systems

Simulation of multiphase flow in the subsurface is well-known to be computationally challenging. While there have been many studies that have explored approaches to overcoming these challenges, they often utilize relatively simple case studies. In this paper, we focus on the unique numerical challenges posed by modeling large-scale engineered subsurface systems, characterized by discrete features embedded in a heterogeneous natural subsurface setting. The man-made features such as shafts, tunnels, and barriers often cause multiple challenges in modeling the domain for multiphase porous media flow. This flow scenario can have a wide range of applications such as nuclear waste repositories, enhanced recovery of a petroleum reservoir, geothermal engineering, and carbon sequestration. An example of these severe numerical challenges is the case of performance assessment (PA) for Waste Isolation Pilot Plant (WIPP), the only operating deep geological repository in the US, which simulates extreme material properties of bedded salt rock formation and extreme contrast due to open excavation next to the formation. The models have extremes not only of permeability and porosity but also of the constitutive models needed for multiphase flow; additionally, they have process models like salt creep closure reducing porosity over time, fracturing in clay and anhydrite interbeds of the bedded salt, gas generation from the waste materials, and unintentional human borehole intrusions in some scenarios. Numerical simulations require the solution of coupled systems of nonlinear PDEs; in our work, we use the open-source simulator PFLOTRAN which is based on Finite Volume discretization. The solution of the nonlinear equations requires use of the Newton-Raphson iteration at each time step, which entails the solution of the linearized Jacobian system at each iteration. The effects of all the processes (i.e., large number of unknowns, highly nonlinear constitutive relations, large contrasts in material properties in short distances) lead to an ill-conditioned Jacobian matrix that severely challenges traditional linear solver, i.e., stabilized biconjugate gradient with block Jacobi incomplete LU preconditioner (BCGS-ILU) leading to non-convergence for traditional Newton-Raphson nonlinear solver causing unacceptably long computation time for each model. This paper presents linear solvers such as constrained pressure residual (CPR) two-stage preconditioner with alternate-block-factorization (ABF) and quasi- implicit pressure and explicit saturation (QIMPES) decouplers and flexible generalized residual solver (FGMRES). The new general-purpose nonlinear solver, Newton trust-region dogleg Cauchy (NTRDC), is also introduced to resolve extreme nonlinearities in the models. We demonstrate the effectiveness of each method relative to the default BCGS-Newton solver. The two best cases had nearly 50 times speed-up and achieved completion of a simulation in 14 hours that never completed due to non-convergence with the default solver. We also investigate the strong scalability of each method and discuss some of the deficiencies found for Block Jacobi preconditioner using parallel domain decomposition, and node packing effects of modern processor architecture.

Preconditioner, Nonlinear, Porous media, Multiphas↗
DOE OSTI2021

Powering the Blue Economy: A Survey of Station-Keeping Methods for Mooringless Platforms

The term “ocean platform” is used to reference everything from stationary, typically moored, buoys to mobile water vehicles, whether they operate on the ocean’s surface or underwater. For certain applications for which relatively stationary station-keeping conditions are desired, the use of mooring systems is not always a viable alternative either for economic, environmental, regulatory, or otherwise practical reasons, or a combination thereof, (e.g., short deployments, sensitive ecosystems, very deep project sites). Maintaining a platform at a single waypoint or reference location without being moored would require additional control systems and a power source to counteract the drift forces that would naturally displace it. Mobile platforms, which are usually untethered except for remotely operated vehicles, typically require energy input to power their station-keeping capabilities so that they hold or control their location in the ocean. Currently, most of these platforms use combustion engines or batteries for this purpose, which, depending on the specific systems, may be costly, pollute the environment, or create limitations on the length of the deployment. However, powering this kind of platforms with surrounding renewable resources (waves, currents, winds, or sun) has been identified as a promising solution to expand their application. The intent of this report is to investigate station-keeping methods for various ocean platforms that are not moored or otherwise anchored to the ocean floor, or another platform or vessel, paying particular interest to technologies that use marine renewable resources to power their operation, because that is of particular interest to the U.S. Department of Energy’s Powering the Blue Economy (PBE) initiative. As a first step, 72 articles and technical reports related to mooringless station-keeping methods were collected for review. The preliminary literature review provided a broad overview of common themes across the literature from which a descriptive methodology for analyzing various platforms was developed. That is, station-keeping methods were categorized based on their predominant energy source and consumption (renewable, nonrenewable, or hybrid if the platform uses renewable and nonrenewable resources equally), and their localization strategy (drift reduction, “path-planning or “waypoint-holding”). In addition, platform types were segregated into the following groups: buoys, surface drifters, and unoccupied surface vehicles (USVs); offshore renewable energy systems; and unoccupied underwater vehicles (UUVs). The main types of station-keeping methods encountered in this report achieve their intended localization strategy by means of drift mitigation, steering, and/or propulsion. Drift mitigation is commonly accomplished via drogues and sea anchors. Stand-along steering subsystems use control surfaces (e.g., ship rudder, wing sail, etc.) that react to ocean currents, waves, or winds to provide varying-degrees of course adjustments. Combined steering and propulsion subsystems include differential thrusters, directional thrusters separate from a primary thruster that cause the platform to pitch up/down or yaw clockwise/counterclockwise, or vectored thrusters that direct the propulsion in a range of directions relative to the platform’s local coordinate system. Propulsion is often achieved by running a motor and applying active control strategies but can also involve buoyancy shifts and using sails to generate lifting forces that propel a platform in a desired direction. Future research is primarily expected to take place in the form of a technoeconomic analysis that would aim to determine the technological viability, cost, and added value of mooringless station-keeping use cases identified through this research, including docking for UUV recharging or for georeferencing drifter buoys, deep-sea floating wind farms, U.S. Navy sonar arrays, and a Pacific Ocean wave buoy network.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2000

X-33, Stepping Stone ot Low Cost Access to Space

In response to the Access to Space Study, which was conducted in 1993 through the Office of Space Systems Development, an advanced technology Reusable Launch Vehicle (RLV) was selected for demonstration. The X-33 was advanced as an demonstration project, to build and test a 53-percent scale prototype of an operational RLV, it would also demonstrate new technologies which would be required to assure the operation of the new RLV. This presentation reviews the progress of the X-33 development and supporting sites. The X-33 design has been completed and fabrication and assembly is progressing well. The X-33 launch site has been completed. The first LH2 tank and engine is in testing. This will lead to the full scale development of VentureStar(tm).

Naftel, J. Chris↗
DOE OSTI2023

Robotic Systems integration for cleanroom SRF assembly at Fermilab

Superconducting Radio Frequency (SRF) cryomodule assembly is a critical process that demands the highest levels of contamination control in a cleanroom to ensure product quality and reliability. Within the cleanroom environment, human-driven activities remain the major source of uncontrolled particulate. Moreover, the precise manual alignment of components often exceeds expected timeframes, increasing the risk of particulate migration into the critical inner space of the SRF resonant cavity, and causing extended discomfort for workers. Automation comes as a natural solution to address these challenges. The goal of this activity is to set up and integrate a robotic system to support cavity coupler installation in the cleanroom environment. Initially, remote control of a 6-axis collaborative robot arm will be implemented as an introductory step towards automation in the cleanroom. Subsequently, the system will be further enhanced by integrating manipulation capabilities through an appropriate end-effector, and computer vision technology to enable accurate pose estimation. This comprehensive approach aims to achieve a fully automated and adaptable assembly process in the partially structured cleanroom environment, thereby enhancing efficiency and mitigating existing challenges for better product quality and workers safety.

42 ENGINEERING↗
NASA NTRS1994

Multidisciplinary design optimization using genetic algorithms

Multidisciplinary design optimization (MDO) is an important step in the conceptual design and evaluation of launch vehicles since it can have a significant impact on performance and life cycle cost. The objective is to search the system design space to determine values of design variables that optimize the performance characteristic subject to system constraints. Gradient-based optimization routines have been used extensively for aerospace design optimization. However, one limitation of gradient based optimizers is their need for gradient information. Therefore, design problems which include discrete variables can not be studied. Such problems are common in launch vehicle design. For example, the number of engines and material choices must be integer values or assume only a few discrete values. In this study, genetic algorithms are investigated as an approach to MDO problems involving discrete variables and discontinuous domains. Optimization by genetic algorithms (GA) uses a search procedure which is fundamentally different from those gradient based methods. Genetic algorithms seek to find good solutions in an efficient and timely manner rather than finding the best solution. GA are designed to mimic evolutionary selection. A population of candidate designs is evaluated at each iteration, and each individual's probability of reproduction (existence in the next generation) depends on its fitness value (related to the value of the objective function). Progress toward the optimum is achieved by the crossover and mutation operations. GA is attractive since it uses only objective function values in the search process, so gradient calculations are avoided. Hence, GA are able to deal with discrete variables. Studies report success in the use of GA for aircraft design optimization studies, trajectory analysis, space structure design and control systems design. In these studies reliable convergence was achieved, but the number of function evaluations was large compared with efficient gradient methods. Applicaiton of GA is underway for a cost optimization study for a launch-vehicle fuel-tank and structural design of a wing. The strengths and limitations of GA for launch vehicle design optimization is studied.

Unal, Resit↗
NASA NTRS1990

Automation of the Environmental Control and Life Support System

The objective of the Environmental Control and Life Support System (ECLSS) Advanced Automation Project is to recommend and develop advanced software for the initial and evolutionary Space Station Freedom (SSF) ECLS system which will minimize the crew and ground manpower needed for operations. Another objective includes capturing ECLSS design and development knowledge for future missions. This report summarizes our results from Phase I, the ECLSS domain analysis phase, which we broke down into three steps: 1) Analyze and document the baselined ECLS system, 2) envision as our goal an evolution to a fully automated regenerative life support system, built upon an augmented baseline, and 3) document the augmentations (hooks and scars) and advanced software systems which we see as necessary in achieving minimal manpower support for ECLSS operations. In addition, Phase I included development of an advanced software life cycle testing tools will be used in the development of the software. In this way, we plan in preparation for phase II and III, the development and integration phases, respectively. Automated knowledge acquisition, engineering, verification, and can capture ECLSS development knowledge for future use, develop more robust and complex software, provide feedback to the KBS tool community, and insure proper visibility of our efforts.

Dewberry, Brandon S.↗
NASA NTRS2017

Adaptive Time Stepping for Transient Network Flow Simulation in Rocket Propulsion Systems

Fluid and thermal transients found in rocket propulsion systems such as propellant feedline system is a complex process involving fast phases followed by slow phases. Therefore their time accurate computation requires use of short time step initially followed by the use of much larger time step. Yet there are instances that involve fast-slow-fast phases. In this paper, we present a feedback control based adaptive time stepping algorithm, and discuss its use in network flow simulation of fluid and thermal transients. The time step is automatically controlled during the simulation by monitoring changes in certain key variables and by feedback. In order to demonstrate the viability of time adaptivity for engineering problems, we applied it to simulate water hammer and cryogenic chill down in pipelines. Our comparison and validation demonstrate the accuracy and efficiency of this adaptive strategy.

Majumdar, Alok K.↗
DOE OSTI2016

Effect of tube processing methods on the texture and grain boundary characteristics of 14YWT nanostructured ferritic alloys

In this paper, texture and microstructure of tubes and plates fabricated from a nanostructured ferritic alloy (14YWT), produced either by spray forming followed by hydrostatic extrusion (Process I) or hot extrusion and cross-rolling a plate followed by hydrostatic tube extrusion (Process II) have been characterized in terms of their effects on texture and grain boundary character. Hydrostatic extrusion results in a combination of plane strain and shear deformations which generate low intensity α- and γ-fiber components of {001}<110> and {111}<110> together with a weak ζ-fiber component of {011}<211> and {011}<011>. In contrast, multi-step plane strain deformation by hot extrusion and cross-rolling of the plate leads to a strong texture component of {001}<110> together with a weaker {111}<112> component. Although the total strains are similar, shear dominated deformation leads to much lower texture indexes compared to plane strain deformations. Further, the texture intensity decreases after hydrostatic extrusion of the alloy plate formed by plane strain deformation, due to a lower number of activated slip systems during shear dominated deformation. Finally and notably, hot extruded and cross-rolled plate subjected to plane strain deformation to ~50% engineering strain creates only a modest population of low angle grain boundaries, compared to the much larger population observed following the combination of plane strain and shear deformation of ~44% engineering strain resulting from subsequent hydrostatic extrusion.

36 MATERIALS SCIENCE↗
NASA NTRS1991

Application of an integrated flight/propulsion control design methodology to a STOVL aircraft

Results are presented from the application of an emerging Integrated Flight/Propulsion Control (IFPC) design methodology to a Short Take Off and Vertical Landing (STOVL) aircraft in transition flight. The steps in the methodology consist of designing command shaping prefilters to provide the overall desired response to pilot command inputs. A previously designed centralized controller is first validated for the integrated airframe/engine plant used. This integrated plant is derived from a different model of the engine subsystem than the one used for the centralized controller design. The centralized controller is then partitioned in a decentralized, hierarchical structure comprising of airframe lateral and longitudinal subcontrollers and an engine subcontroller. Command shaping prefilters from the pilot control effector inputs are then designed and time histories of the closed loop IFPC system response to simulated pilot commands are compared to desired responses based on handling qualities requirements. Finally, the propulsion system safety and nonlinear limited protection logic is wrapped around the engine subcontroller and the response of the closed loop integrated system is evaluated for transients that encounter the propulsion surge margin limit.

Garg, Sanjay↗
NASA NTRS2000

STS-99 Countdown Status Briefing

The primary objective of the STS-99 mission was to complete high resolution mapping of large sections of the Earth's surface using the Shuttle Radar Topography Mission (SRTM), a specially modified radar system. This radar system produced unrivaled 3-D images of the Earth's Surface. The mission was launched at 12:31 on February 11, 2000 onboard the space shuttle Endeavour. This tape shows a pre-launch briefing. The panel members are George Diller, NASA Public Affairs; Scott Higginbotham, SRTM Payload Manager; Steve Altemus, NASA Test Director; and Ed Priselac, Meteorologist. The briefing opens with an announcement by Mr Diller that there were no further developments with the engine problems, and requests that questions about that issue be held for another press briefing. Steve Altemus summarized the situation and the steps to be taken. Scott Higginbotham reported that there were no problems with the mission hardware. Ed Priselac reported favorable weather for tanking and launch, and at emergency landing sites.

Source record↗
NASA NTRS2004

Space-based Science Operations Grid Prototype

Grid technology is the up and coming technology that is enabling widely disparate services to be offered to users that is very economical, easy to use and not available on a wide basis. Under the Grid concept disparate organizations generally defined as "virtual organizations" can share services i.e. sharing discipline specific computer applications, required to accomplish the specific scientific and engineering organizational goals and objectives. Grids are emerging as the new technology of the future. Grid technology has been enabled by the evolution of increasingly high speed networking. Without the evolution of high speed networking Grid technology would not have emerged. NASA/Marshall Space Flight Center's (MSFC) Flight Projects Directorate, Ground Systems Department is developing a Space-based Science Operations Grid prototype to provide to scientists and engineers the tools necessary to operate space-based science payloads/experiments and for scientists to conduct public and educational outreach. In addition Grid technology can provide new services not currently available to users. These services include mission voice and video, application sharing, telemetry management and display, payload and experiment commanding, data mining, high order data processing, discipline specific application sharing and data storage, all from a single grid portal. The Prototype will provide most of these services in a first step demonstration of integrated Grid and space-based science operations technologies. It will initially be based on the International Space Station science operational services located at the Payload Operations Integration Center at MSFC, but can be applied to many NASA projects including free flying satellites and future projects. The Prototype will use the Internet2 Abilene Research and Education Network that is currently a 10 Gb backbone network to reach the University of Alabama at Huntsville and several other, as yet unidentified, Space Station based science experimenters. There is an international aspect to the Grid involving the America's Pathway (AMPath) network, the Chilean REUNA Research and Education Network and the University of Chile in Santiago that will further demonstrate how extensive these services can be used. From the user's perspective, the Prototype will provide a single interface and logon to these varied services without the complexity of knowing the where's and how's of each service. There is a separate and deliberate emphasis on security. Security will be addressed by specifically outlining the different approaches and tools used. Grid technology, unlike the Internet, is being designed with security in mind. In addition we will show the locations, configurations and network paths associated with each service and virtual organization. We will discuss the separate virtual organizations that we define for the varied user communities. These will include certain, as yet undetermined, space-based science functions and/or processes and will include specific virtual organizations required for public and educational outreach and science and engineering collaboration. We will also discuss the Grid Prototype performance and the potential for further Grid applications both space-based and ground based projects and processes. In this paper and presentation we will detail each service and how they are integrated using Grid

Bradford, Robert N.↗
NASA NTRS2004

Method Developed for Improving the Thermomechanical Properties of Silicon Carbide Matrix Composites

Today, a major thrust for achieving engine components with improved thermal capability is the development of fiber-reinforced silicon-carbide (SiC) matrix composites. These materials are not only lighter and capable of higher use temperatures than state-of-the-art metallic alloys and oxide matrix composites (approx. 1100 C), but they can provide significantly better static and dynamic toughness than unreinforced silicon-based monolithic ceramics. However, for successful application in advanced engine systems, the SiC matrix composites should be able to withstand component service stresses and temperatures for the desired component lifetime. Since the high-temperature structural life of ceramic materials is typically controlled by creep-induced flaw growth, a key composite property requirement is the ability to display high creep resistance under these conditions. Also, because of the possibility of severe thermal gradients in the components, the composites should provide maximum thermal conductivity to minimize the development of thermal stresses. State-of-the-art SiC matrix composites are typically fabricated via a three-step process: (1) fabrication of a component-shaped architectural preform reinforced by high-performance fibers, (2) chemical vapor infiltration of a fiber coating material such as boron nitride (BN) into the preform, and (3) infiltration of a SiC matrix into the remaining porous areas in the preform. Generally, the highest performing composites have matrices fabricated by the CVI process, which produces a SiC matrix typically more thermally stable and denser than matrices formed by other approaches. As such, the CVI SiC matrix is able to provide better environmental protection to the coated fibers, plus provide the composite with better resistance to crack propagation. Also, the denser CVI SiC matrix should provide optimal creep resistance and thermal conductivity to the composite. However, for adequate preform infiltration, the CVI SiC matrix process typically has to be conducted at temperatures below 1100 C, which results in a SiC matrix that is fairly dense, but contains metastable atomic defects and is nonstoichiometric because of a small amount of excess silicon. Because these defects typically exist at the matrix grain boundaries, they can scatter thermal phonons and degrade matrix creep resistance by enhancing grain-boundary sliding. To eliminate these defects and improve the thermomechanical properties of ceramic composites with CVI SiC matrices, researchers at the NASA Glenn Research Center developed a high-temperature treatment process that can be used after the CVI SiC matrix is deposited into the fiber preform.

Bhatt, Ramakrishna T.↗
NASA NTRS2018

Next Steps in Planetary Protection for Human Spaceflight

Planetary protection is defined as: a) the prevention of contamination of extraterrestrial bodies by terrestrial microorganisms, and b) biohazard containment of returned samples from bodies in the Solar System that could harbor life.1 While the majority of interplanetary missions to date have involved robotic exploration, future missions will include human explorers. Current planetary protection requirements do not address the unique challenges associated with human exploration. The purpose of this abstract is to review planetary protection efforts for crewed missions and provide a forward plan for implementing them at the systems level. Article IX of the UN Outer Space Treaty of 1967 provides the definition of planetary protection, outlined above.1 COSPAR holds the international standard in line with this treaty2, while NASA's Planetary Protection Policy (NPD 8020.7G) outlines the U.S. implementation of the COSPAR standard. 3;4 NPI 8020.7 groups future human spaceflight planetary protection studies as follows: 1) microbial monitoring, 2) contamination mitigation and control, and 3) environmental effects. Additionally, a NPI 8020.7 outlines a five-step plan for forward work: 1) a literature review, 2) community inputs, 3) completion of recommended studies, 4) developing a draft NPR, and 5) implementation with NASA teams. The literature review was published in 2016.5 Inputs from the community were gathered at the Planetary Protection Knowledge Gaps for Human Extraterrestrial Missions, held in 2015.6 Johnson and Race (2016) outlined notional requirements and prioritized studies needed before final requirements can be produced. This prior work sets the stage for completing the necessary studies and finalizing planetary protection requirements for human spaceflight. We propose a continuation of the systems engineering approach adopted thus far. The challenges associated with the implementation of notional requirements will be quantified in detailed discussions with internal stakeholders. The status and results of high-priority studies that have been completed since 2016 or are ongoing will be incorporated into discussions with stakeholders. In this way, we plan to bridge the gap between the science behind planetary protection and the engineering development that will implement it, allowing finalized planetary protection requirements to be developed for future human space missions.

Mitchell, Julie↗
DOE OSTI2020

Rapid Assessment of Autoignition Propensity in Novel Fuels and Blends

We developed a computational strategy to correlate bulk combustion metrics of novel fuels and blends in the low-temperature autoignition regime with measurements of key combustion intermediates in a small-volume, dilute, high-pressure reactor. We used neural net analysis of a large simulation dataset to obtain an approximate correlation and proposed experimental and computational steps needed to refine such a predictive correlation. We also designed and constructed a high-pressure laboratory apparatus to conduct the proposed measurements and demonstrated its performance on three canonical fuels: n-heptane, i-octane, and dimethyl ether.

10 SYNTHETIC FUELS↗
DOE OSTI2024

Thermal Management System for an Electric Machine With Additively Manufactured Hollow Conductors With Integrated Heat Pipes

Here, this paper discusses steps taken to develop a novel thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal finite element analysis is used to determine optimum heat transfer coefficient of the convective boundaries. For some of the convective boundaries, fin-based surface area enhancement is required to reach a target combined overall heat transfer coefficient and surface area performance (UA). This enhancement is worked out using a combination of the Engineering Equation Solver tool and 3D thermal FEA. The thermal management system's UA, and by extension its specific power, sensitivity to coolant temperature is explored. Temperature distribution plots of optimized machine components are also presented and discussed. Lastly, additional heat pipe testing is carried out to study its maximum heat transfer capability's sensitivity to condenser coolant temperature and configuration.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Creep Property of Intermetallic Dispersive Steels for Nuclear Applications

To meet the materials performance demands of next-generation nuclear and high-temperature energy systems, a new class of intermetallic-dispersive steels (IDS) has been designed through integrated computational thermodynamics and alloy design strategies. The IDS alloys incorporate coherent L1₂ (γ′-Ni₃Al) nanoprecipitates within an Fe–Ni–Cr austenitic matrix, engineered to achieve both high temperature strength and thermodynamic stability while suppressing the formation of detrimental δ-Ni₃Nb and η-Ni₃Ti phases. Initial creep testing of Ti-IDS and TiTa-IDS alloys demonstrates rupture lives comparable to or exceeding those of Inconel 718 and ODS steels, despite being fabricated through conventional ingot metallurgy. Step-load creep tests identified a stress threshold near 300–350 MPa for the onset of tertiary creep, and in-situ neutron diffraction experiments on Ti-IDS revealed clear load partitioning between the matrix and γ′ precipitates: elastic strain is shared by both phases, while plastic strain localizes in the matrix. These results confirm that stable γ′–matrix interfaces play a dominant role in retarding dislocation motion and enhancing creep resistance. In FY26, the program will conduct repeat creep rupture testing of TiTa-IDS at 650 °C/400 MPa, initiate long-term rupture testing of TiNb-IDS, and perform TEM-based microstructural characterization to elucidate dislocation–precipitate interactions and microstructural stability. Collectively, these efforts will establish the mechanistic foundation for next-generation high-temperature structural materials based on the IDS concept.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗