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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 991 records · Page 55

High-Speed Ring Bus

The high-speed ring bus at the Jet Propulsion Laboratory (JPL) allows for future growth trends in spacecraft seen with future scientific missions. This innovation constitutes an enhancement of the 1393 bus as documented in the Institute of Electrical and Electronics Engineers (IEEE) 1393-1999 standard for a spaceborne fiber-optic data bus. It allows for high-bandwidth and time synchronization of all nodes on the ring. The JPL ring bus allows for interconnection of active units with autonomous operation and increased fault handling at high bandwidths. It minimizes the flight software interface with an intelligent physical layer design that has few states to manage as well as simplified testability. The design will soon be documented in the AS-1393 standard (Serial Hi-Rel Ring Network for Aerospace Applications). The framework is designed for "Class A" spacecraft operation and provides redundant data paths. It is based on "fault containment regions" and "redundant functional regions (RFR)" and has a method for allocating cables that completely supports the redundancy in spacecraft design, allowing for a complete RFR to fail. This design reduces the mass of the bus by incorporating both the Control Unit and the Data Unit in the same hardware. The standard uses ATM (asynchronous transfer mode) packets, standardized by ITU-T, ANSI, ETSI, and the ATM Forum. The IEEE-1393 standard uses the UNI form of the packet and provides no protection for the data portion of the cell. The JPL design adds optional formatting to this data portion. This design extends fault protection beyond that of the interconnect. This includes adding protection to the data portion that is contained within the Bus Interface Units (BIUs) and by adding to the signal interface between the Data Host and the JPL 1393 Ring Bus. Data transfer on the ring bus does not involve a master or initiator. Following bus protocol, any BIU may transmit data on the ring whenever it has data received from its host. There is no centralized arbitration or bus granting. The JPL design provides for autonomous synchronization of the nodes on the ring bus. An address-synchronous latency adjust buffer (LAB) has been designed that cannot get out of synchronization and needs no external input. Also, a priority-driven cable selection behavior has been programmed into each unit on the ring bus. This makes the bus able to connect itself up, according to a maximum redundancy priority system, without the need for computer intervention at startup. Switching around a failed or switched-off unit is also autonomous. The JPL bus provides a map of all the active units for the host computer to read and use for fault management. With regard to timing, this enhanced bus recognizes coordinated timing on a spacecraft as critical and addresses this with a single source of absolute and relative time, which is broadcast to all units on the bus with synchronization maintained to the tens of nanoseconds. Each BIU consists of up to five programmable triggers, which may be programmed for synchronization of events within the spacecraft of instrument. All JPL-formatted data transmitted on the ring bus are automatically time-stamped.

Wysocky, Terry↗

A study of methods to predict and measure the transmission of sound through the walls of light aircraft

The objectives are: measurement of dynamic properties of acoustical foams and incorporation of these properties in models governing three-dimensional wave propagation in foams; tests to measure sound transmission paths in the HP137 Jetstream 3; and formulation of a finite element energy model. In addition, the effort to develop a numerical/empirical noise source identification technique was completed. The investigation of a design optimization technique for active noise control was also completed. Monthly progress reports which detail the progress made toward each of the objectives are summarized.

Bernhard, R. J.↗

Development of cable drive systems for an automated assembly project

In a robotic assembly project, a method was needed to accurately position a robot and a structure which the robot was to assemble. The requirements for high precision and relatively long travel distances dictated the use of cable drive systems. The design of the mechanisms used in translating the robot and in rotating the assembly under construction is discussed. The design criteria are discussed, and the effect of particular requirements on the design is noted. Finally, the measured performance of the completed mechanism is compared with design requirements.

Monroe, Charles A., Jr.↗

CFD-Based Design of Turbopump Inlet Duct for Reduced Dynamic Loads

Numerical simulations have been completed for a variety of designs for a 90 deg elbow duct. The objective is to identify a design that minimizes the dynamic load entering a LOX turbopump located at the elbow exit. Designs simulated to date indicate that simpler duct geometries result in lower losses. Benchmark simulations have verified that the compressible flow codes used in this study are applicable to these incompressible flow simulations.

Rothermel, Jeffry↗

Deployable Cryocooler Based Cryomodule

Superconducting Radio Frequency (SRF) linear accelerators (linacs) have shown tremendous promise in extending the intensity frontier of particle accelerator technology. However, they are large and complex systems, requiring a central refrigeration system and complex piping to distribute liquid helium and nitrogen to the accelerating cavities. In response to these problems, RadiaBeam Technologies, LLC. proposes to develop a small mobile cryomodule that can be safely deployed to its planned field location. The scope of this work is to provide RadiaBeam with the specifications for a complete 650 MHz RF cavity model that can be incorporated into a compact SRF accelerator. Fermilab’s contribution will involve sharing contact resistance measurements, design parameters, and solid models. Design parameters will include the cavity frequency and gradient, length of the linac, number of cryocoolers, etc. This will ensure that the design is useful for practical linacs. A complete cryomodule design is envisioned. Radiabeam will design the cryomodule based on input from Fermilab’s experience on conduction cooling and the needs for a compact SRF accelerator.

43 PARTICLE ACCELERATORS↗

Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned

Historically, regulatory barriers have precluded nuclear plant safety-related (SR) Instrumentation and Control (I&C) system modernizations. These barriers have been largely addressed by industry and United States Nuclear Regulatory Commission (NRC) efforts, including development of the License Amendment Request (LAR) Alternate Review (AR) process for digital I&C upgrades. The U.S. Department of Energy (DOE) and the Idaho National Laboratory (INL) are supporting a SR I&C pilot upgrade at the Limerick Generating Station (LGS) to demonstrate this process and capturing associated lessons learned for the benefit of industry. In 2021, a paper summarizing lessons learned as captured in INL/EXT-20-59809, Safety Related Instrumentation & Control Pilot Upgrade Initial Scoping Phase Implementation Report and Lessons Learned was presented at the 12th NPIC & HMIT conference. It is recommended that readers of this paper review reference 1 or the associated Nuclear Journal paper for context. This paper summarizes activities performed and lessons learned for the conceptual design phase and portions of the detailed design phase as captured in INL/RPT-23-XXXX, “Safety-Related Instrumentation and Control Pilot Upgrade: Conceptual - Detailed Design Phase Report and Lessons Learned.” The portions of the effort covered by reference 2 include conceptual design phase activities from December 2020, through completion in November 2021, and detailed design activities through September 2022. These efforts and associated detailed documentation in reference 3 are intended to support similar industry upgrades as a foundation stone for a Digital Transformation that will improve plant safety, reliability, and operational performance while lowering plant total cost of ownership.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Research in extreme ultraviolet and far ultraviolet astronomy

Analysis and interpretation continued on data generated by the flight of 27.086 in April of 1986 and by the successful UVX mission. Optical and mechanical design of the 1 meter EUV telescope, planned for launch with the large SPARTAN type carrier, ASTRO-SPAS, was also continued. The major effort centered on the preparation of flight 27.106, scheduled to launch in September, 1986. Work which was performed included: design of the skins and bulkheads; completion of the optical, mechanical, and electrical design; purchase of the major components of the instruments; assemblage of the electrical components; and performance of theoretical work, to support the data interpretation.

Bowyer, C. S.↗

Wide-Field Infrared Survey Telescope (WFIRST) Interim Report

The New Worlds, New Horizons (NWNH) in Astronomy and Astrophysics 2010 Decadal Survey prioritized the community consensus for ground-based and space-based observatories. Recognizing that many of the community s key questions could be answered with a wide-field infrared survey telescope in space, and that the decade would be one of budget austerity, WFIRST was top ranked in the large space mission category. In addition to the powerful new science that could be accomplished with a wide-field infrared telescope, the WFIRST mission was determined to be both technologically ready and only a small fraction of the cost of previous flagship missions, such as HST or JWST. In response to the top ranking by the community, NASA formed the WFIRST Science Definition Team (SDT) and Project Office. The SDT was charged with fleshing out the NWNH scientific requirements to a greater level of detail. NWNH evaluated the risk and cost of the JDEM-Omega mission design, as submitted by NASA, and stated that it should serve as the basis for the WFIRST mission. The SDT and Project Office were charged with developing a mission optimized for achieving the science goals laid out by the NWNH re-port. The SDT and Project Office opted to use the JDEM-Omega hardware configuration as an initial start-ing point for the hardware implementation. JDEM-Omega and WFIRST both have an infrared imager with a filter wheel, as well as counter-dispersed moderate resolution spectrometers. The primary advantage of space observations is being above the Earth's atmosphere, which absorbs, scatters, warps and emits light. Observing from above the atmosphere enables WFIRST to obtain precision infrared measurements of the shapes of galaxies for weak lensing, infrared light-curves of supernovae and exoplanet microlensing events with low systematic errors, and infrared measurements of the H hydrogen line to be cleanly detected in the 1<z<2 redshift range important for baryon acoustic oscillation (BAO) dark energy measurements. The Infrared Astronomical Satellite (IRAS), the Cosmic Background Explorer (COBE), Herschel, Spitzer, and Wide-field Infrared Sur-vey Explorer (WISE) are all space missions that have produced stunning new scientific advances by going to space to observe in the infrared. This interim report describes progress as of June 2011 on developing a requirements flowdown and an evaluation of scientific performance. An Interim Design Reference Mission (IDRM) configuration is presented that is based on the specifications of NWNH with some refinements to optimize the design in accordance with the new scientific requirements. Analysis of this WFIRST IDRM concept is in progress to ensure the capability of the observatory is compatible with the science requirements. The SDT and Project will continue to refine the mission concept over the coming year as design, analysis and simulation work are completed, resulting in the SDT s WFIRST Design Reference Mission (DRM) by the end of 2012.

Green, J.↗

High Temperature Anode Recycle Blower for Solid Oxide Fuel Cell, Phase II (Final Report)

Broad commercialization of solid oxide fuel cells (SOFCs) requires anode offgas recycle blowers (ARCB) that are specifically designed for handling the challenging operating conditions presented by the SOFC process gases. Otherwise, they can be susceptible to frequent maintenance, low reliability, and short life. This report presents details of a DOE-funded Phase II effort conducted by Mohawk Innovative Technology, Inc. (MiTi®) for the development and testing of an oil-free, low cost, high-temperature centrifugal ARCB based on compliant foil bearing (CFB) technology for support of a 100 kW solid oxide fuel cell power plant. This Phase II builds on the results of a successful Phase I development project that resulted in the demonstration of a low TRL-6 prototype, shown in Figure 1. This Phase II final report presents design improvements over the Phase I prototype, presents the assembled test ARCBs, and discusses the advantages of this novel technology, particularly its long life and maintenance-free operation, which are derived from the use of CFBs. Also included are preliminary techno-economic analysis considerations for cost-effective deployment of the technology. The specific objectives of this project, as stated in the statement of program objectives (SOPO) were 1) to follow the methodology of design for manufacturing (or manufacturability) and assembly for implementing improvements identified as part of the Phase I effort with the purpose of reducing cost, enabling mass production, and facilitating the commercialization of a revised ARCB design, and 2) to fabricate four complete ARCB units based on the revised design and demonstrating their performance in both a laboratory setting and in an actual SOFC power plant. Execution of this SOPO would be supported by a number of technical tasks resulting in the fabrication and testing of the prototypes. To this end, MiTi continued the teaming relationship started during Phase I of the program with subcontracting partner FuelCell Energy, Inc. (FCE), which integrated (under a parallel effort funded by DOE Award DE-FE0026199) a modular 200 kWe SOFC power plant. MiTi and FCE coordinated to ultimately incorporate one of MiTi’s ARCB prototypes into one of the 100 kWe SOFC Modular Power Blocks (MPB) that constitute the core of FCE’s SOFC power plant for in-situ long-duration testing. Additionally, MiTi would explore the scalability and extendibility of the technology to other applications, as well as conduct a basic techno-economic analysis.

03 NATURAL GAS↗

Robotic Tank Refurbishment System (TRS) for U.S. Naval Vessels - 18395

A remotely-operated Tank Refurbishment System (TRS) has been developed to reduce the personnel hazards associated with manual refurbishment of U.S. Naval vessel tanks. This system is capable of using a variety of tools to complete the necessary refurbishment tasks within the tanks. In 2017, the design for this system was completed, and preliminary testing was successfully completed. (authors)

42 ENGINEERING↗

Advanced composite aileron for L-1011 transport aircraft

Design and evaluation of alternate concepts for the major subcomponents of the advanced composite aileron (ACA) was completed. From this array of subcomponents, aileron assemblies were formulated and evaluated. Based on these analyses a multirib assembly with graphite tape/syntactic core covers, a graphite tape front spar, and a graphite fabric rib was selected for development. A weight savings of 29.1 percent (40.8 pounds per aileron) is predicted. Engineering cost analyses indicate that the production cost of the ACA will be 7.3 percent less than the current aluminum aileron. Fabrication, machining, and testing of the material evaluation specimens for the resin screening program was completed. The test results lead to the selection of Narmco 5208 resin for the ACA. Other activities completed include: the detailed design of the ACA, construction of a three dimensional finite element model for structural analysis, and formulation of detail plans for material verification and process development.

Source record↗

Brassboard Astrometric Beam Combiner (ABC) Development for the Space Interferometry Mission (SIM)

The Astrometric Beam Combiner (ABC) is a critical element of the Space Interferometry Mission (SIM) that performs three key functions: coherently combine starlight from two siderostats; individually detect starlight for angle tracking; and disperse and detect the interferometric fringes. In addition, the ABC contains: a stimulus, cornercubes and shutters for in-orbit calibration; several tip/tilt mirror mechanisms for in-orbit alignment; and internal metrology beam launcher for pathlength monitoring. The detailed design of the brassboard ABC (which has the form, fit and function of the flight unit) is complete, procurement of long-lead items is underway, and assembly and testing is expected to be completed in Spring 2009. In this paper, we present the key requirements for the ABC, details of the completed optical and mechanical design as well as plans for assembly and alignment.

PlanetQuest↗

Solar Steam on Demand

INTRODUCTION: This Report summarizes the research and development project performed by Sunvapor and the subrecipient National Renewable Energy Laboratory (NREL) during the period of 10/01/2018-9/30/2021. The work was aimed at the economic integration of solar steam with an industrial process, and in particular, the advantages that a novel type of thermal energy storage and collector design could bring to the system. The completed work includes experimental research on the storage material, design of the collector, engineering of a complete solar steam plant, and economic analysis. The plant was, in the end, not constructed, due to COVID-19 impacts to the project host. PURPOSE: The purpose of the project was to test the hypothesis that a levelized cost of heat (LCOH) of 2¢/kWh delivered to a steam-consuming process, including energy discharged from storage, could be feasibly achieved. PROJECT OBJECTIVES: For Budget Period 1 our objectives were to engineer a prototype industrial solar steam generation system, and design and test a Latent Heat Energy Storage (LHES) lab-scale system. For Budget Period 2 our objectives were to construct and test the solar steam prototype plant, and to build and factory-test a full LHES module. For Budget Period 3 our objective was to integrate the storage module with the solar steam generator, show successful long duration energy tests of the combined system, and use the results to project the LCOH of delivered steam to a second-generation plant. PROJECT OUTCOMES: Various phase change materials (PCMs) for the LHES were tested for compatibility with industrial steam uses as measured by phase change temperature, stability of latent heat of fusion, and their corrosive effects on steel (the heat exchanger material). Two of these materials (sodium formate and sodium/ potassium) showed potential to meet the technical criteria. The estimated cost of a complete LHES module with these materials did not meet economic targets. The developmental collector design builds from previous work to exploit the potential cost advantages of a spaceframe of lumber construction. Design improvements were achieved in assembly efficiency and structural performance. A complete engineering package was completed for the solar steam system without storage that included the developmental as well as commercial arrays. The plant was permitted for construction. The storage CAPEX for a reference plant was estimate to be greater than $\$ 57$/kWh. The LCOH of the system without storage and with developmental collectors of lumber construction was projected to be 2¢/kWh, assuming a FCR of 8.2% over thirty years. PROJECT MILESTONES: The Milestones fully achieved in the first Budget Period includes obtaining a Letter of Intent from an industrial steam-consuming project host, issuance of a construction permit, and corrosion resistance. The Milestone that was partly achieved was the degradation in the latent heat of fusion. Milestones associated with Budget Periods 2 and 3, related to the construction and operation of the plant were not achieved as a result of the host shutting down the plant due to COVID-19 impacts. CONCLUSIONS: Sunvapor was able to secure an agreement with a host to build a fully engineered and permitted solar steam plant that met the host’s economic goals. As a basis for comparison, the solar field design was comprised of eight commercial collector arrays and one developmental Green Parabolic Trough Collector (GPTC) array. The projected LCOH with a solar field entirely populated with a second generation GPTC met the goal of 2¢/kWh. The experimental program concerning the PCM indicated the feasibility of meeting their technical requirements for industrial steam uses. The cost of the complete LHES exceeded its $\$ 14$/kWh target, and therefore the inclusion of LHES could not be economically justified. Due to COVID-19 impacts on the host, the solar steam plant was not constructed.

14 SOLAR ENERGY↗

Environmental exposure effects on composite materials for commercial aircraft

Activities reported include completion of the program design tasks, resolution of a high fiber volume problem and resumption of specimen fabrication, fixture fabrication, and progress on the analysis methodology and definition of the typical aircraft environment. Program design activities including test specimens, specimen holding fixtures, flap-track fairing tailcones, and ground exposure racks were completed. The problem experienced in obtaining acceptable fiber volume fraction results on two of the selected graphite epoxy material systems was resolved with an alteration to the bagging procedure called out in BAC 5562. The revised bagging procedure, involving lower numbers of bleeder plies, produces acceptable results. All required laminates for the contract have now been laid up and cured. Progress in the area of analysis methodology has been centered about definition of the environment that a commercial transport aircraft undergoes. The selected methodology is analagous to fatigue life assessment.

Hoffman, D. J.↗

Optimization techniques applied to passive measures for in-orbit spacecraft survivability

Spacecraft designers have always been concerned about the effects of meteoroid impacts on mission safety. The engineering solution to this problem has generally been to erect a bumper or shield placed outboard from the spacecraft wall to disrupt/deflect the incoming projectiles. Spacecraft designers have a number of tools at their disposal to aid in the design process. These include hypervelocity impact testing, analytic impact predictors, and hydrodynamic codes. Analytic impact predictors generally provide the best quick-look estimate of design tradeoffs. The most complete way to determine the characteristics of an analytic impact predictor is through optimization of the protective structures design problem formulated with the predictor of interest. Space Station Freedom protective structures design insight is provided through the coupling of design/material requirements, hypervelocity impact phenomenology, meteoroid and space debris environment sensitivities, optimization techniques and operations research strategies, and mission scenarios. Major results are presented.

Mog, Robert A.↗

FY2022 Progress Report for Advanced Re-fabrication/Re-instrumentation Capability Development

In support of performing follow-on irradiation experiments with previously irradiated materials, the Halden Reactor Project developed unique and state of the art capabilities to refabricate and re-instrument previously irradiated materials. Such materials were used in in-pile tests at the Halden reactor, and out-of-pile tests for example using furnaces as a heat source. The decision to close the Halden Reactor Project results in the loss of this refabrication and re-instrumentation capability. As a result, the United States (U.S.) Department of Energy (DOE) has determined to develop refabrication and re-instrumentation capability at the unique shielded facilities at Idaho National Laboratory (INL). The development of refabrication capability has been completed and demonstrated. This report focuses on the complementary aspects of reinstrumentation and the progress to-date. Halden spent nearly 30 years developing both refabrication and re-instrumentation. Collaboration with Halden is allowing Idaho National Laboratory (INL) to develop this capability much more rapidly. In FY-21 the results include development of the capability to drill annular center holes in ceramic UO2 fuel pellets, development of fuel rod end caps with feedthroughs for centerline instrumentation inside the rodlet, The procurement of both fuel drilling and welding demonstration equipment from Halden, evaluation of surface thermocouple attachments to support better understanding of temperature measurement uncertainties, and finally, the conceptual design of a new shielded enclosure where advanced refabrication and re-instrumentation equipment can be housed. In FY-22, the results include; Completing set up of the drilling and welding modules procured from Halden, and early experimental trials using that equipment.; Completing set up of an out-of-cell circumferential weld system to allow for further weld development to take place and support fabrication of fuel for fresh fuel experiments.; Evaluation of the Hot Fuel Examination Facility (HFEF) infrastructure to support future installation of advanced re-fabrication/re-instrumentation equipment, specifically related to necessary infrastructure for cryo-drilling.; Developments in dry-drilling alternative. Including experimental studies showing cordierite is the most suitable surrogate for UO 2 for performing drilling studies. That drilling performance is enhanced when a fuel-clad bonding condition is simulated.; Conceptual design completed for attaching surface thermocouples to irradiated fuel in support of TWIST capsule experiments. The authors would like to thank the numerous colleagues at INL and Halden who provided support in accomplishing this work. Their support both material and intellectual is invaluable in advancing the state of the art and establishing the capabilities for refabrication and re-instrumentation at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

CFD-based Design of LOX Pump Inlet Duct for Reduced Dynamic Loads

Numerical simulations have been completed for a variety of designs for a 90 deg elbow duct. The objective is to identify a design that minimizes the dynamic load entering a LOX turbopump located at the elbow exit. Designs simulated to date indicate that simpler duct geometries result in lower losses. Benchmark simulations have verified that the compressible flow code used in this study is applicable to these incompressible flow simulations.

Rothermel, Jeffry↗