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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Zeolite Degradation: An Investigation of CO2 Capacity Loss of 13x Sorbent

System testing of the Carbon Dioxide Removal and Compression System (CRCS) has revealed that sufficient CO2 removal capability was not achieved with the designed system. Subsystem component analysis of the zeolite bed revealed that the sorbent material suffered significant degradation and CO2 loading capacity loss. In an effort to find the root cause of this degradation, various factors were investigated to try to reproduce the observed performance loss. These factors included contamination by vacuum pump oil, o-ring vacuum grease, loading/unloading procedures, and operations. This paper details the experiments that were performed and their results.

Air Revitalization↗
NASA NTRS2017

Zeolite Degradation: An Investigation of CO2 Capacity Loss of 13x Sorbent

System testing of the Carbon Dioxide Removal and Compression System (CRCS) has revealed that sufficient CO2 removal capability was not achieved with the designed system. Subsystem component analysis of the zeolite bed revealed that the sorbent material suffered significant degradation and CO2 loading capacity loss. In an effort to find the root cause of this degradation, various factors were investigated to try to reproduce the observed performance loss. These factors included contamination by vacuum pump oil, o-ring vacuum grease, loadingunloading procedures, and operations. This paper details the experiments that were performed and their results.

ECLSS↗
NASA NTRS2010

Miniature Piezoelectric Shaker for Distribution of Unconsolidated Samples to Instrument Cells

The planned Mars Science Laboratory mission requires inlet funnels for channeling unconsolidated powdered samples from the sampling and sieving mechanisms into instrument test cells, which are required to reduce cross-contamination of the samples and to minimize residue left in the funnels after each sample transport. To these ends, a solid-state shaking mechanism has been created that requires low power and is lightweight, but is sturdy enough to survive launch vibration. The funnel mechanism is driven by asymmetrically mounted, piezoelectric flexure actuators that are out of the load path so that they do not support the funnel mass. Each actuator is a titanium, flextensional piezoelectric device driven by a piezoelectric stack. The stack has Invar endcaps with a half-spherical recess. The Invar is used to counteract the change in stress as the actuators are cooled to Mars ambient temperatures. A ball screw is threaded through the actuator frame into the recess to apply pre-stress, and to trap the piezoelectric stack and endcaps in flexure. During the vibration cycle of the flextensional actuator frame, the compression in the piezoelectric stack may decrease to the point that it is unstressed; however, because the ball joint cannot pull, tension in the piezoelectric stack cannot be produced. The actuators are offset at 120 . In this flight design, redundancy is required, so three actuators are used though only one is needed to assist in the movement. The funnel is supported at three contact points offset to the hexapod support contacts. The actuator surface that does not contact the ring is free to expand. Two other configurations can be used to mechanically tune the vibration. The free end can be designed to drive a fixed mass, or can be used to drive a free mass to excite impacts (see figure). Tests on this funnel mechanism show a high density of resonance modes between 1 and 20 kHz. A subset of these between 9 and 12 kHz was used to drive the CheMin actuators at 7 V peak to peak. These actuators could be driven by a single resonance, or swept through a frequency range to decrease the possibility that a portion of the funnel surface was not coincident with a nodal line (line of no displacement). The frequency of actuation can be electrically controlled and monitored and can also be mechanically tuned by the addition of tuning mass on the free end of the actuator. The devices are solid-state and can be designed with no macroscopically moving parts. This design has been tested in a vacuum at both Mars and Earth ambient temperatures ranging from 30 to 25 C

Sherrit, Stewart↗
DOE OSTI2021

Impacts of Substrate Thinning on FPGA Performance and Reliability [Slides]

Substrate thinning is necessary in devices with flip-chip BGA packages to enable both radiation testing and component qualification and high-spatial resolution beam-based failure analysis methods. We investigated three factors affecting device performance: subsurface damage from the thinning process, reduced heat spreading in thin substrates, and changes in device switching speed. We conclude subsurface damage to crystalline Si caused by the thinning process is removable with sufficient SiO 2 slurry polishing. Local temperature differences increase minimally in devices thinned to 3 μm. Compressive stress in the Si increases globally after device thinning and leads to slowing of ring oscillator frequency by about 0.5% compared to full-thickness devices. Future work will include extending the results to submicron Si thickness values, which also has important benefits for failure analysis, debug, and security assessments. We also plan to extend this type of work to other FPGAs and other devices like memory and processors.

36 MATERIALS SCIENCE↗
NASA NTRS1993

Viscoelastic analysis of seals for extended service life

The space station is being developed for a service life of up to thirty years. As a consequence, the design requirements for the seals to be used are unprecedented. Full scale testing to assure the selected seals can satisfy the design requirements are not feasible. As an alternative, a sub-scale test program (2) has been developed by MSFC to calibrate the analysis tools to be used to certify the proposed design. This research has been conducted in support of the MSFC Integrated Seal Test Program. The ultimate objective of this research is to correlate analysis and test results to qualify the analytical tools which in turn, are to be used to qualify the flight hardware. Seals are simple devices, in wide spread use. The most common type of seal is the O-ring. O-ring seals are typically rings of rubber with a circular cross section. The rings are placed between the surfaces to be sealed, usually in a groove of some design. The particular design may differ based on a number of different factors. This research is focused on O-rings that are staticly compressed by perpendicular clamping forces, commonly referred to as face seals. In this type of seal the O-ring is clamped between the sealing surfaces by loads perpendicular to the circular cross section.

Bower, Mark V.↗
DOE OSTI2025

Investigation of the temperature-dependent failure processes in PVD Cr-coated ZIRLO nuclear fuel cladding using in situ X-ray micro-tomography imaging

In this work, an accident tolerant fuel cladding system with Cr coating deposited using physical vapour deposition (PVD) method onto commercial Optimized ZIRLO™ was studied. The cladding tubes were machined into C-rings and loaded to failure under compression with real-time synchrotron micro-X-ray computed tomography (XCT) imaging at room temperature (RT), 345 °C, 650 °C and 950 °C in argon (Ar) atmosphere. The mechanical behaviour and failure processes were found strongly temperature-dependent where the Cr coating showed brittle fracture at RT and 345 °C, ductile fracture at 650 °C and a reversion to brittle fracture at 950 °C. Nanoindentation measurements and scanning electron microscopy (SEM) imaging were conducted on the materials after high temperature testing. It was found that recrystallisation of the Cr coating occurred at elevated temperatures, which significantly affected its local properties hence the failure behaviour at different temperatures. This work represents the first in situ 3D XCT observation of progressive failure processes in PVD Cr-coated ZIRLO claddings up to 950 °C providing critical insights into its brittle-to-ductile transition (BDTT) behaviour and subsequent ductile-to-brittle reversion with the increase in temperature. Moreover, results are compared with other PVD Cr-coated Zircaloy materials from open literature; the influences of the coating microstructure and local properties on the failure stress/strain and fracture processes are discussed.

Yuan, Guanjie↗
NASA NTRS2005

Apparatus for Testing Flat Specimens of Thermal Insulation

An apparatus has been developed to implement an improved method of testing flat-plate specimens of thermal-insulation materials for cryogenic application. The method includes testing under realistic use conditions that could include vacuum and mechanical loading at a pressure up to 70 psi (=0.48 MPa). The apparatus can accommodate a rigid or flexible specimen having thickness up to 1.25 in. (=3.2 cm) and diameters between 6 and 10 in. (about 15.2 and 25.4 cm, respectively). Typical test conditions include boundary temperatures between 77 K and 373 K and vacuum/interstitial gas filling at a pressure between 10(exp -6) torr (=1.3 x 10(exp -4) Pa) and 760 torr (atmospheric pressure =0.1 MPa). The interstitial gas could be N2, He, CO2, or any other suitable gas to which the insulation is expected to be exposed in use. Relative to prior apparatuses and testing methods, this apparatus and the testing method that it implements offer advantages of relative simplicity and ease of use. The basic principle of operation of the apparatus is that of boil-off calorimetry, using liquid nitrogen or any other suitable liquid that boils at a desired temperature below ambient temperature. Comparative rates of flow of heat through the thicknesses of the specimens (heat-leak rates) and apparent-thermal-conductivity values are obtained from tests of specimens. Absolute values of heat-leak rates and apparent thermal conductivities are computed from a combination of (1) the aforementioned comparative values and (2) calibration factors obtained by testing reference specimens of materials that have known thermal-insulation properties. The apparatus includes a full complement of temperature sensors, a vacuum pump and chamber, a monitoring and control system, and tools and fixtures that enable rapid and reliable installation and removal of specimens. A specimen is installed at the bottom of the vacuum chamber, and a cold-mass assembly that includes a tank is lowered into position above and around the specimen (see figure). A spring-based compensating fixture helps to ensure adequate thermal contact with possibly irregular specimen surfaces. For a high-compression test, the springs can be replaced with spacers. A flat circular load cell at the bottom of the chamber measures the compressive load on the specimen. Once the desired compressive-load, temperature, and vacuum/gas-filling conditions are established, testing begins. During a test, all measurements are recorded by use of a portable data-acquisition system and a computer. The total heat-leak rate is measured and calculated as the boil-off flow rate multiplied by the latent heat of vaporization. The parasitic heat leak (to the side of the specimen and to the top and side of the cold-mass tank) is reduced to a small fraction of the total heat leak by use of a combination of multilayer-insulation (MLI) shield rings, reflective film, a fiberglass/epoxy centering ring, and a bulk fill of aerogel beads. This combination eliminates the need for a cryogenic guard chamber used in a typical prior apparatus to reduce the parasitic heat leak.

Fesmire, James E.↗
NASA NTRS1998

Feasibility Assessment of Thermal Barrier Seals for Extreme Transient Temperatures

The assembly joints of modem solid rocket motor cases are generally sealed using conventional O-ring type seals. The 5500+ F combustion gases produced by rocket motors are kept a safe distance away from the seals by thick layers of phenolic insulation. Special compounds are used to fill insulation gaps leading up to the seals to prevent a direct flowpath to them. Design criteria require that the seals should not experience torching or charring during operation, or their sealing ability would be compromised. On limited occasions, NASA has observed charring of the primary O-rings of the Space Shuttle solid rocket nozzle assembly joints due to parasitic leakage paths opening up in the gap-fill compounds during rocket operation. NASA is investigating different approaches for preventing torching or charring of the primary O-rings. One approach is to implement a braided rope seal upstream of the primary O-ring to serve as a thermal barrier that prevents the hot gases from impinging on the O-ring seals. This paper presents flow, resiliency, and thermal resistance for several types of NASA rope seals braided out of carbon fibers. Burn tests were performed to determine the time to burn through each of the seals when exposed to the flame of an oxyacetylene torch (5500 F), representative of the 5500 F solid rocket motor combustion temperatures. Rope seals braided out of carbon fibers endured the flame for over six minutes, three times longer than solid rocket motor burn time. Room and high temperature flow tests are presented for the carbon seals for different amounts of linear compression. Room temperature compression tests were performed to assess seal resiliency and unit preloads as a function of compression. The thermal barrier seal was tested in a subscale "char" motor test in which the seal sealed an intentional defect in the gap insulation. Temperature measurements indicated that the seal blocked 2500 F combustion gases on the upstream side with very little temperature rise on the downstream side.

Steinetz, Bruce M.↗
NASA NTRS1977

Direct-connect tests of hydrogen-fueled supersonic combustors

Direct-connect tests of hydrogen-fueled supersonic combustors were performed using arc-heated air at combustor inlet Mach numbers of 2.9 to 3.2. Various axisymmetric combustor geometries of 5.89 and 6.96 cm (inner diameter) inlet were investigated; the fuel was injected from the wall either from a ring of equally spaced holes normal to the air stream, or from a circumferential slot oriented 45 deg downstream. The hole-type injectors consistently gave better results. The effects of various parameters are examined, and the performance comparison procedure is described. A theoretical model of the supersonic combustion process which includes a precombustion shock-compression is used to explain the character of the observed pressure distributions and to assess the effects of the measured heat transfer rates, deduced wall shear, and combustor geometry on performance.

Waltrup, P. J.↗
NASA NTRS2016

Combustion Dynamics and Stability Modeling of a Liquid Oxygen/RP-2 Oxygen-Rich Staged Combustion Preburner and Thrust Chamber Assembly with Gas-Centered Swirl Coaxial Injector Elements

The Combustion Stability Tool Development (CSTD) project, funded by the Air Force Space and Missile Systems Center, began in March 2015 supporting a renewed interest in the development of a liquid oxygen/hydrocarbon, oxygen-rich combustion engine. The project encompasses the design, assembly, and hot-fire testing of the NASA Marshall Space Flight Center 40-klbf Integrated Test Rig (MITR). The test rig models a staged-combustion configuration by combining an oxygen-rich preburner (ORPB), to generate hot gas, with a thrust chamber assembly (TCA) using gas-centered swirl coaxial injector elements. There are five separately designed interchangeable injectors in the TCA that each contain 19- or 27- injector elements. A companion paper in this JANNAF conference describes the design characteristics, rationale, and fabrication issues for all the injectors. The data acquired from a heavily instrumented rig encompasses several injectors, several operating points, and stability bomb tests. Another companion paper in this JANNAF conference describes this test program in detail. In this paper, dynamic data from the hot-fire testing is characterized and used to identify the responses in the ORPB and TCA. A brief review of damping metrics are discussed and applied as a measure of stability margin for damped acoustic modes. Chug and longitudinal combustion stability models and predictions are described which includes new dynamic models for compressible flow through an orifice and a modification to incorporate a third feed line for inclusion of the fuel-film coolant. Flow-acoustics finite element modeling is used to investigate the anticipated TCA acoustics, the effects of injector element length on stability margin, and the potential use of an ORPB orifice trip ring for improving longitudinal stability margin.

Casiano, M. J.↗
NASA NTRS1944

The inward bulge type buckling of monocoque cylinders I : calculation of the effect upon the buckling stress of a compressive force, a nonlinear direct stress distribution, and a shear force

In the present part I of a series of reports on the inward bulge type buckling of monocoque cylinders the buckling load in combined bending and compression is first derived. Next the reduction in the buckling load because of a nonlinear direct stress distribution is determined. In experiments nonlinearity may result from an inadequate stiffness of the end attachments in actual airplanes from the existence of concentrated loads or cut-outs. The effect of a shearing force upon the critical load is investigated through an analysis of the results of tests carried out at GALCIT with 55 reinforced monocoque cylinders. Finally, a simple criterion of general instability is presented in the form of a buckling inequality which should be helpful to the designer of a monocoque in determining the sizes of the rings required for excluding the possibility of inward bulge type buckling.

Hoff, N J↗
DOE OSTI2023

Water-Resistant Container Testing CNUT INGB Container Design (Rev. 1)

The purpose of this report is to detail the results of water ingress testing conducted on the 5Qt Castle Nut In-Glovebox (5QtCNUT INGB) container design and discuss these results against the water-resistant container requirements of TA55-AP- 522 and PA-RD-01009. The CNUT is a general-purpose container option for material storage inside of a glovebox and/or as an approved non-hermetically sealed inner of an approved packaging configuration inside of an approved outer container as listed in PA-RD-01022. The CNUT containment boundary consists of a filtered lid and deep drawn body with welded collar all made of 316L stainless steel, an aluminum bronze spin down ring to provide compression of a to Viton® O-ring to create a seal for closure and containment.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Implementation of Fiber Optic Sensing System on Sandwich Composite Cylinder Buckling Test

The National Aeronautics and Space Administration (NASA) Engineering and Safety Center Shell Buckling Knockdown Factor Project is a multicenter project tasked with developing new analysis-based shell buckling design guidelines and design factors (i.e., knockdown factors) through high-fidelity buckling simulations and advanced test technologies. To validate these new buckling knockdown factors for future launch vehicles, the Shell Buckling Knockdown Factor Project is carrying out structural testing on a series of large-scale metallic and composite cylindrical shells at the NASA Marshall Space Flight Center (Marshall Space Flight Center, Alabama). A fiber optic sensor system was used to measure strain on a large-scale sandwich composite cylinder that was tested under multiple axial compressive loads up to more than 850,000 lb, and equivalent bending loads over 22 million in-lb. During the structural testing of the composite cylinder, strain data were collected from optical cables containing distributed fiber Bragg gratings using a custom fiber optic sensor system interrogator developed at the NASA Armstrong Flight Research Center. A total of 16 fiber-optic strands, each containing nearly 1,000 fiber Bragg gratings, measuring strain, were installed on the inner and outer cylinder surfaces to monitor the test article global structural response through high-density real-time and post test strain measurements. The distributed sensing system provided evidence of local epoxy failure at the attachment-ring-to-barrel interface that would not have been detected with conventional instrumentation. Results from the fiber optic sensor system were used to further refine and validate structural models for buckling of the large-scale composite structures. This paper discusses the techniques employed for real-time structural monitoring of the composite cylinder for structural load introduction and distributed bending-strain measurements over a large section of the cylinder by utilizing unique sensing capabilities of fiber optic sensors.

FOS↗
NASA NTRS2019

Helium Balloon Valve Improvement

The NASA Balloon Program Office (BPO), located at Wallops Flight Facility asked the Mechanical Systems Branch (Code 548) to improve the design of their balloon valve. BPO uses two main types of balloons, Zero Pressure Balloon (ZPB) and Super Pressure Balloon (SPB), which both use the valve. It is used for termination of the ZPB, and inflation and termination of the SPB. During launch campaigns the valve showed signs of helium leakage which lead the BPO to ask for an improvement. As part of a Professional Readiness Engineering Program (PREP), research and review of the current valve was conducted and a new design was prepared. The current custom designed valve consists of a "pie" plate that is actuated up and down via a gear rack that is driven by a globe motor. When closed the knife edge of the pie plate bites into a silicone gasket to seal the structure. Unfortunately, the gasket material permanently deforms after being compressed and the plate itself bends under the force induced by the motor, introducing two possible helium leak paths. The new custom designed valve utilizes o-rings instead of one gasket to reduce the possibility of leakage from permanent deformation. One o-ring seals the valve structure to its mating surface and a spring energized o-ring is used in a piston design to seal the valve once it's closed. The design also utilizes different materials to increase stiffness and strength so that it is less likely to bend under the force from the motor. Currently the new valve has finished the design and analysis phases and is proceeding towards manufacturing and testing.

Seo, Lindsey↗
DOE OSTI2022

H-Canyon Jumper Gasket Sealing Evaluation

H-Canyon Documented Safety Analysis approved December 2019 credits the leak integrity of HCanyon (HCA) process tanks, piping, and jumpers in preventing the release of radioactive material in a post seismic environment. Demonstration of leak tightness capability for this equipment was achieved through substantial analytical effort. However, one potential weak point that affects leak integrity exists at the gasketed joint between Hanford Connectors (HC) and nozzles. Review of the HCA Crane Log over a three-year period indicates the HCs periodically leak. Savannah River National Laboratory (SRNL) was requested to perform gasket compression tests that evaluate gasket relaxation characteristics, i.e., creep, and provide improvements to the HC installation process that can reduce or eliminate the frequency of leaks at HCs. A HC torque value of 312 ft-lbf is the target value used because it is the minimum torque value, with 95% confidence, when an unlubricated HC is impacted for standard sealing period of 9 seconds.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Low-Cost, High-Performance Carbon Fiber for Compressed Natural Gas Storage Tanks (Final Technical Report – Down Select Report)

The aim of this project is to reduce the cost of Type IV, carbon fiber (CF) composite overwrap compressed gas storage tanks by reducing the cost of CF and CF composites. The project team worked to reduce the cost of CF by exploring and testing opportunities for a low-cost alternative precursor material for CF production to supplant market-dominant and costly polyacrylonitrile (PAN). Concurrently, the team aimed to reduce the cost of the tanks at the composite level by improving the interfacial adhesion between the fibers and the matrix resin through the incorporation of low-cost nanoparticles recycled from waste materials, which would reduce the volume of costly CF required to achieve the same tank performance. At the end of the first year, the project team selected mesophase pitch as the primary precursor candidate from a field of materials based on the superior mechanical performance and cost-saving potential. During the second year, the team produced CFs derived from mesophase pitch achieving an average tensile strength of 365.6 ksi and average tensile modulus of 40.74 Msi. Facility availability for spinning and converting these fibers at greater scale has hindered scale-up demonstration, but the team has identified opportunities to conduct this work in the near term. Cost modeling shows that these mesophase pitch-derived CFs can be up to 40% less expensive than PAN-derived CFs due to the lower cost of the feedstock material, higher throughput, greater conversion yield, and lower cost spinning method and compared to PAN. Additionally, the team has demonstrated at lab-scale that nanoparticle coating CFs can significantly increase the interfacial shear strength and load transfer efficiency of CFs in a matrix. Single filament pull-out testing showed a 27% average increase in max interfacial shear strength due to this coating. A continuous method of applying these coatings to a tow of CF has been developed for scale-up. 26 m tows of coated CFs were produced using this system and formed into composite ring samples for ASTM ring burst testing. Issues with the testing protocol have limited assessment of these results. A prototype Type IV tank was designed to meet ANSI HGV2 standards, and the design criteria set out by DOE, using the CF properties developed by the team paired with a proprietary resin matrix, a polyamide liner, and aluminum end bosses. The tank weighs 153.1 kg and with a total capacity of 5.8 kg H2 (5.6 kg usable), which yields a gravimetric capacity of 1.17 kWh/kg. Cost modeling predicts that the tank will have a projected cost of $15.73/kWh. Tank performance modeling does not include considerations for fiber-matrix load transfer efficiency improvements offered by nanoparticle coating method.

08 HYDROGEN↗
DOE OSTI2022

Evaluation of 3D Simulation Capabilities within xRAGE using a Suite of Test Problems

This presentation describes a 3D verification and validation suite for xRAGE. Three verification test problems for hydrodynamics are presented: the Kidder ball problem, the Verney shell problem, and a 5-material compression problem. There is excellent agreement between 2D and 3D XRAGE simulation results for these problems, and between the xRAGE results and the benchmark solutions. In addition, two 3D ICF test problems are presented, based on an OMEGA direct drive capsule experiment, and on a NIF indirect drive capsule experiment. These two ICF test problems are used to evaluate two hydrodynamic methods within xRAGE. In addition to hydrodynamics the simulations also include three temperature plasma physics, thermal conduction and radiation diffusion. When simulating either capsule in 3D the newer unsplit hydrodynamic method in xRAGE produces more vorticity relative to the older default method. For the indirect drive capsule the 3D simulations are in reasonable agreement with the experimental values of ion temperature and neutron production. Unstable 3D vortex rings are present near the DT ice/carbon interface which enhance the confinement of the DT ice.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1997

Residual Stress Measurements After Proof and Flight: ETP-0403

The intent of this testing was to evaluate the residual stresses that occur in and around the attachment details of a case stiffener segment that has been subjected to flight/recovery followed by proof loading. Not measured in this test were stresses relieved at joint disassembly due to out-of-round and interference effects, and those released by cutting the specimens out of the case segment. The test article was lightweight case stiffener segment 1U50715, S/N L023 which was flown in the forward stiffener position on flight SRM 14A and in the aft position on flight SRM24A. Both of these flights were flown with the 3 stiffener ring configuration. Stiffener L023 had a stiffener ring installed only on the aft stub in its first flight, and it had both rings installed on its second flight. No significant post flight damage was found on either flight. Finally, the segment was used on the DM-8 static test motor in the forward position. No stiffener rings were installed. It had only one proof pressurization prior to assignment to its first use, and it was cleaned and proof tested after each flight. Thus, the segment had seen 3 proof tests, two flight pressurizations, and two low intensity water impacts prior to manufacturing for use on DM-8. On DM-8 it received one static firing pressurization in the horizontal configuration. Residual stresses at the surface and in depth were evaluated by both the x-ray diffraction and neutron beam diffraction methods. The x-ray diffraction evaluations were conducted by Technology for Energy Corporation (TEC) at their facilities in Knoxville, TN. The neutron beam evaluations were done by Atomic Energy of Canada Limited (AECL) at the Chalk River Nuclear Laboratories in Ontario. The results showed general agreement with relatively high compressive residual stresses on the surface and moderate to low subsurface tensile residual stresses.

Webster, Ronald L..↗