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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

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NASA NTRS1989

Spacecraft contamination experience

Effective contamination control must encompass all aspects of ground and flight from design of the system through the end of mission life. Design systems are needed to minimize sensitivity to contamination, ease of cleaning, and contaminant production. Facilities and procedures are critical to maintaining cleanliness during ground operations. Flight operations should be planned so as to minimize contamination. More data from flights are required to assess the adequacy of designs and operations. Standards and specifications should include contamination control requirements.

Borson, E. N.↗

NASA NTRS1979

Computer-aided fracture mechanics life prediction analysis

The fracture mechanics analysis and computer logic used to perform design life predictions is described. Initial part-through crack defects are analyzed under the conditions of constant-amplitude loading to predict the number of loading cycles applied before breakthrough or failure. A criterion is provided to predict the transition from part-through crack growth characteristics to through crack growth characteristics. A breakthrough criterion is also provided.

Peterson, D. E.↗

DOE OSTI2025

Development of a Robust Reference Electrode in Aggressive Chemical and Radiation Environments in the Hanford Waste Tanks

The Hanford site stores more than 200 million liters of radioactive and chemically hazardous wastes from the production of weapons materials. The wastes are stored in 177 underground carbon-steel storage tanks, separated between 149 single shell tanks (SSTs) and 28 double shell tanks (DSTs). The DSTs provide critical retrieval and interim storage before the waste is vitrified in the Waste Treatment and Isolation Plant (WTP). The tanks will need to remain in-service far beyond the initial 40-year design life, and effective corrosion control practices must remain in force to extend the tanks’ lifespans. This effort includes direct measurements of corrosion rate (e.g., ultrasonic measurements and corrosion coupons) and electrochemical processes (e.g., linear polarization measurements and open circuit potential measurements). The Hanford site began monitoring the corrosion potential in select DSTs in 2008. Of the 45 reference electrodes that have been installed, 29 have failed and 6 others provided unreliable results. DOE-EM is supporting a 3-year program to develop a chemical and radiation resistant reference electrode for application in the Hanford tanks. The first year of the program focused on understanding the failure mechanism for the reference electrodes and identification of candidate construction materials that would mitigate degradation of the electrodes in the waste environment. During the second year of the program, the objectives were to: 1) test candidate materials under simulated waste conditions, 2) design components that will extend the service life of the electrode, 3) fabricate materials for prototype reference electrodes, and 4) assemble prototype reference electrodes for accelerated testing. The reference electrode is constructed of four principal parts: 1) junction, 2) casing, 3) inner chamber backfill materials, and 4) the sensing wire. Principally, improvements of the junction, casing, and inner chamber backfill materials are being pursued. The junction material at the interface between the waste and the inner chamber of the reference electrode was identified as a critical component in the failure of the reference electrodes. Nine candidate replacement junction materials were tested under simulated waste conditions to evaluate permeation rate. These materials included a variety of polymeric and ceramic materials, some of which were 3-D printed. Thus far, porous polyvinylidene fluoride materials have performed satisfactorily and are being considered for prototype development. The commercial electrode casing materials in general have performed well. Additionally, 3-D printing of chemically and mechanically stable materials is being investigated as a means for further improvement in fabrication consistency. SRNL has also investigated altering the reference electrode design to extend the service life. The new design of the interior of the reference electrode casing creates a longer, more tortuous path between the junction material and the electrode sensing wire. A finite element model was used to optimize the design without adversely impacting the circuit resistance of the electrode during the measurements, thus preserving the measurement accuracy while enhancing the service life. The inner chamber back fill materials are also critical to the performance of the reference electrode. Materials that are resistant to intruding tank waste and provide a conductive path to the sensing wire were investigated. Gel and powder materials that are interspersed with a conductive chloride bearing material were tested for their influence on diffusion and electrode resistance. All the investigated materials and components will be assembled, with collaboration from commercial vendors, to fabricate the initial prototypes. Accelerated testing of the prototypes will be initiated in Year 2 of the program and will be completed in Year 3. A recommendation on the materials of construction and the design of the new robust reference electrode will be presented to the Hanford tank farm facility.

Sykes, Kiana [Savannah River National Laboratory (↗

NASA NTRS1972

Investigation of safe-life fail-safe criteria for the space shuttle

An investigation was made to determine the effects of a safe-life design approach and a fail-safe design approach on the space shuttle booster vehicle structure, and to recommend any changes to the structural design criteria. Two configurations of the booster vehicle were considered, one incorporating a delta wing (B-9U configuration) and the other a swept wing (B-16B configuration). Several major structural components of the booster were studied to determine the fatigue life, safe-life, and fail-safe capabilities of the baseline design. Each component was investigated to determine the practicability of applying a safe-life or fail-safe design philosophy, the changes such design approaches might require, and the impact of these changes on weight, cost, development plans, and performance.

Source record↗

DOE OSTI2020

Preliminary description of a new creep-fatigue design method that reduces over conservatism and simplifies the high temperature design process

The report provides the initial description of a new creep-fatigue design method for structural components in high temperature nuclear service. The new method is based on an integrated elastic-perfectly plastic (EPP) analysis and Simplified Model Test (SMT) approach that reduces over conservatism, improves the treatment of elastic follow up, and simplifies the design procedure, when compared with the current creep-fatigue design methods in ASME Boiler and Pressure Vessel Code. Developing the design charts for the EPP-SMT design method requires extrapolating SMT test data as a function of hold time and follow up factor. The report develops the preliminary design charts for Alloy 617 at temperatures between 800°C and 950°C by combining two extrapolation approaches developed in a previous work. The report also presents a comparative analysis between the EPP-SMT design method and the current ASME creep-fatigue design methods by evaluating design life of two sample geometries under different loading conditions. Results from the comparative analysis verify the EPP-SMT design charts but suggest the requirement of additional test data in the low strain range regime for improving the extrapolation procedure that will further reduce the over conservatism in the creep-fatigue damage evaluation. The report also concludes that the EPP-SMT design procedure can account for effect of primary load on creep-fatigue life by using a fixed, bounding value of follow up in constructing the design charts. The conclusions to this report describe the future work required to complete this new design method so it can be codified through a nuclear Code Case.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1982

Flexible radiator thermal vacuum test report

Two flexible, deployable/retraction radiators were designed and fabricated. The two radiator panels are distinguishable by their mission life design. One panel is designed with a 90 percent probability of withstanding the micrometeoroid environment of a low earth orbit for 30 days. This panel is designated the soft tube radiator after the PFA Teflon tubes which distribute the transport fluid over the panel. The second panel is designed with armored flow tubes to withstand the same micrometeoroid environment for 5 years. It is designated the hard tube radiator after its stainless steel flow tubes. The thermal performance of the radiators was tested under anticipated environmental conditions. The two deployment systems of the radiators were evaluated in a thermal vacuum environment.

Oren, J. A.↗

NASA NTRS2017

Material Analysis and System Design for Exploration Life Support Systems 2017

Advanced Environmental Control and Life Support System (ECLSS) design is critical for manned space flight beyond Earth. Current systems enable extended missions in low-Earth orbit, but for deep-space missions, not only will astronauts be outside the reach of resupply operations from Earth but they will also need to handle malfunctions and compensate for the degradation of materials. These two daunting challenges must be overcome for long-term independent space flight. In order to solve the first, separation and recycling of onboard atmosphere is required. Current systems utilize space vacuum to fully regenerate CO2 sorbent beds, but this is not sustainable. The second challenge stems from material and performance degradation due to operational cycling and on-board contaminants. This report will review the recent work by the ECLSS team at Marshall Space Flight Center towards overcoming these challenges by characterizing materials via novel methods and by assessing new air revitalization systems.

Knox, Jim↗

DOE OSTI2025

FY25 status report on the addition of candidate materials in Class B Code Case

This report provides the time-dependent allowable stress calculation strategy leveraging the limited creep rupture tests data generated to support the allowable stress for 100,000 hours in American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section II, Part D. A variable confidence index procedure to extrapolate material properties to support 500,000 hours design life is discussed. Time-dependent allowable stresses for Class B component design and analysis are presented for Grade 1 and Grade 2 of Alloy 625. The presented data extrapolation and allowable stress calculation method will support new material addition using limited creep rupture data in the new ASME Boiler and BPVC, Section III, Division 5, Class B rules.

Part D↗

NASA NTRS2013

Configuration Management at NASA

NASA programs are characterized by complexity, harsh environments and the fact that we usually have one chance to get it right. Programs last decades and need to accept new hardware and technology as it is developed. We have multiple suppliers and international partners Our challenges are many, our costs are high and our failures are highly visible. CM systems need to be scalable, adaptable to new technology and span the life cycle of the program (30+ years). Multiple Systems, Contractors and Countries added major levels of complexity to the ISS program and CM/DM and Requirements management systems center dot CM Systems need to be designed for long design life center dot Space Station Design started in 1984 center dot Assembly Complete in 2012 center dot Systems were developed on a task basis without an overall system perspective center dot Technology moves faster than a large project office, try to make sure you have a system that can adapt

Doreswamy, Rajiv↗

NASA NTRS2017

Axiomatic Design of Space Life Support Systems

Systems engineering is an organized way to design and develop systems, but the initial system design concepts are usually seen as the products of unexplained but highly creative intuition. Axiomatic design is a mathematical approach to produce and compare system architectures. The two axioms are:- Maintain the independence of the functional requirements.- Minimize the information content (or complexity) of the design. The first axiom generates good system design structures and the second axiom ranks them. The closed system human life support architecture now implemented in the International Space Station has been essentially unchanged for fifty years. In contrast, brief missions such as Apollo and Shuttle have used open loop life support. As mission length increases, greater system closure and increased recycling become more cost-effective.Closure can be gradually increased, first recycling humidity condensate, then hygiene wastewater, urine, carbon dioxide, and water recovery brine. A long term space station or planetary base could implement nearly full closure, including food production. Dynamic systems theory supports the axioms by showing that fewer requirements, fewer subsystems, and fewer interconnections all increase system stability. If systems are too complex and interconnected, reliability is reduced and operations and maintenance become more difficult. Using axiomatic design shows how the mission duration and other requirements determine the best life support system design including the degree of closure.

Axiomatic design↗

NASA NTRS1993

SP-100 control drive assembly development

The SP-100 is an electrical generating nuclear power system for space operation. This paper describes the nuclear reactor control systems and the methods used to assure reliable performance for the 10-year design life. Reliable performance is achieved by redundancy and by selecting highly reliable components and design features. Reliability is quantified by analysis using established reliability data. Areas lacking reliability data are identified for development testing. A specific development test description is provided as an example to demonstrate how this process is meeting the system reliability goals.

Gleason, Thomas↗

NASA NTRS2003

Minimum impulse thruster valve design and development

The design and development of a minimum impulse thruster valve was conducted, by Moog, under contract by NASA's Jet Propulsion Laboratory, California Institute of Technology, for deep space propulsion systems. The effort was focused on applying known solenoid design techniques scaled to provide a 1 -millisecond response capability for monopropellant, hydrazine ACS thruster applications. The valve has an extended operating temperature range of 20(deg)F to +350(deg)F with a total mass of less than 25 grams and nominal power draw of 7 watts. The design solution resulted in providing a solenoid valve that is one-tenth the scale of the standard product line. The valve has the capability of providing a mass flow rate of 0.0009 pounds per second hydrazine. The design life of 1,000,000 cycles was demonstrated both dry and wet. Not all design factors scaled as expected and proved to be the focus of the final development effort. These included the surface interactions, hydrodynamics and driver electronics. The resulting solution applied matured design approaches to minimize the program risk with innovative methods to address the impacts of scale.

impulse thruster valve↗

DOE OSTI2022

Designing Cladded Components for High Temperature Nuclear Service: Part I—Analysis Methods

Use of corrosion-resistant cladding can greatly extend the design life of structural components in many advanced reactor systems. However, there are currently no ASME design rules for cladded components to guard against creep-fatigue failure and ratcheting strain accumulation in elevated temperature nuclear service. This paper, presented in two parts, addresses this gap by proposing a design strategy for cladded components that do not require long-term testing of clad materials. The proposed approach relies on approximate design analysis methods for two types of clad materials—a soft clad that creeps much faster than and has lower yield stress than the class A base material and a hard clad that creeps much slower than and has higher yield stress than the class A base material. Part I discusses the approximate analysis strategies for the clad materials—treat a soft clad as perfectly compliant and a hard clad as linear elastic—and Part II develops a complete set of design rules for each of the two types of cladded components. In conclusion, finite element analyses of representative high temperature reactor components show that the proposed design analysis methods can bound the design quantities in soft cladded components and approximate the design quantities in hard cladded components.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1998

Active Pattern Factor Control for Gas Turbine Engines

Small variations in fuel/air mixture ratios within gas turbine combustors can result in measurable, and potentially detrimental, exit thermal gradients. Thermal gradients can increase emissions, as well as shorten the design life of downstream turbomachinery, particularly stator vanes. Uniform temperature profiles are usually sought through careful design and manufacturing of related combustor components. However, small componentto-component variations as well as numerous aging effects degrade system performance. To compensate for degraded thermal performance, researchers are investigating active, closed-loop control schemes.

May, James E.↗

NASA NTRS2014

Don't Trust a Management Metric, Especially in Life Support

Goodhart's law states that metrics do not work. Metrics become distorted when used and they deflect effort away from more important goals. These well-known and unavoidable problems occurred when the closure and system mass metrics were used to manage life support research. The intent of life support research should be to develop flyable, operable, reliable systems, not merely to increase life support system closure or to reduce its total mass. It would be better to design life support systems to meet the anticipated mission requirements and user needs. Substituting the metrics of closure and total mass for these goals seems to have led life support research to solve the wrong problems.

life support↗

NASA NTRS2016

Early Engagement of Safety and Mission Assurance Expertise Using Systems Engineering Tools: A Risk-Based Approach to Early Identification of Safety and Assurance Requirements

Decades of systems engineering practice have demonstrated that the earlier the identification of requirements occurs, the lower the chance that costly redesigns will needed later in the project life cycle. A better understanding of all requirements can also improve the likelihood of a design's success. Significant effort has been put into developing tools and practices that facilitate requirements determination, including those that are part of the model-based systems engineering (MBSE) paradigm. These efforts have yielded improvements in requirements definition, but have thus far focused on a design's performance needs. The identification of safety & mission assurance (S&MA) related requirements, in comparison, can occur after preliminary designs are already established, yielding forced redesigns. Engaging S&MA expertise at an earlier stage, facilitated by the use of MBSE tools, and focused on actual project risk, can yield the same type of design life cycle improvements that have been realized in technical and performance requirements.

Requirement↗

NASA NTRS2019

Evaluation Methodologies for Early Conceptual Design Using Virtual Reality and Physical Test Environments

In this study, human factor design engineers wanted to know, by using subject matter experts (SMEs), if there would be any differences in testing low-fidelity conceptual designs in a physical environment compared to a digital/virtual one. Results indicated that when testing a design concept at this early stage, a high correlation between the two environments exists, meaning SMEs found little to no difference when evaluating a design in either a physical or a digital/virtual environment. There are advantages and limitations to both environments. The virtual world gave the experts a better sense of the microgravity space environment and the relationships of space and human presence that are difficult to simulate in a 1-g physical environment. However, the interaction between human and mechanics is better enhanced in the physical world compared to the virtual world. These advantages and limitations of each environment are important; however, cost is also an important consideration when early design concepts are being used. With the cost analysis of materials, hardware, and labor conducting for this study, virtual reality showed a 68% decrease in cost over the physical mock-up build. Thus, taking all aspects of the study into consideration, at this early design life cycle phase, virtual reality shows great promise as an evaluation environment for testing early design concepts that will cost less, give more options, and increase designer’s time to design.

Harry L. Litaker Jr↗

DOE OSTI2024

Experimental and Analytical Verification of ASME Section IiII Division 5 Creep-Fatigue Design Rules

The continuous advancement of structural materials and the growing demands for more reliable and economical structural components in high-temperature reactor applications have necessitated the development of comprehensive design methodologies and design rules. Mechanical degradation of structural components at elevated temperatures subjected to cyclic deformation is controlled by the creep-fatigue damage. Over the past few decades, diligent research efforts have been dedicated to refining the development of elevated temperature design rules in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC), Section III, Division 5 and to develop conservative design rules that can effectively guard against the risk of creep-fatigue failure. In ASME Section III, Division 5, for a design to pass the creep-fatigue acceptance criteria, creep damage and fatigue damage are evaluated separately, and these damages must not violate the bi-linear creep-fatigue interaction diagram, i.e., the so-called D-diagram. The creep-fatigue damage evaluation procedure assumes that the effects of the actual cyclic loading sequence can be bounded by assuming that the individual loading cycles are uniformly distributed throughout the component design life. In this study, creep-fatigue experiments with variable amplitudes and loading sequencies were designed and performed on Alloy 617 at high temperatures. The results were analyzed to evaluate the loading history effect on creep-fatigue damage accumulation and to verify the assumptions for the creep-fatigue evaluation design rules.

36 - MATERIALS SCIENCE↗