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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

Lunar Module ECS (Environmental Control System) - Design Considerations and Failure Modes

Design considerations and failure modes for the Lunar Module (LM) Environmental Control System (ECS) are described. An overview of the the oxygen supply and cabin pressurization, atmosphere revitalization, water management and heat transport systems are provided. Design considerations including reliability, flight instrumentation, modularization and the change to the use of batteries instead of fuel cells are discussed. A summary is provided for the LM ECS general testing regime.

Interbartolo, Michael↗
NASA NTRS2015

Multipurpose Pressure Vessel Scanner and Photon Doppler Velocimetry

Critical flight hardware typically undergoes a series of nondestructive evaluation methods to screen for defects before it is integrated into the flight system. Conventionally, pressure vessels have been inspected for flaws using a technique known as fluorescent dye penetrant, which is biased to inspector interpretation. An alternate method known as eddy current is automated and can detect small cracks better than dye penetrant. A new multipurpose pressure vessel scanner has been developed to perform internal and external eddy current scanning, laser profilometry, and thickness mapping on pressure vessels. Before this system can be implemented throughout industry, a probability of detection (POD) study needs to be performed to validate the system’s eddy current crack/flaw capabilities. The POD sample set will consist of 6 flight-like metal pressure vessel liners with defects of known size. Preparation for the POD includes sample set fabrication, system operation, procedure development, and eddy current settings optimization. For this, collaborating with subject matter experts was required. This technical paper details the preparation activities leading up to the POD study currently scheduled for winter 2015/2016. Once validated, this system will be a proven innovation for increasing the safety and reliability of necessary flight hardware.Additionally, testing of frangible joint requires Photon Doppler Velocimetry (PDV) and Digital Image Correlation instrumentation. There is often noise associated with PDV data, which necessitates a frequency modulation (FM) signal-to-noise pre-test. Generally, FM radio works by varying the carrier frequency and mixing it with a fixed frequency source, creating a beat frequency which is represented by audio frequency that can be heard between about 20 to 20,000 Hz. Similarly, PDV reflects a shifted frequency (a phenomenon known as the Doppler Effect) from a moving source and mixes it with a fixed source frequency, which results in a beat frequency. However, for PDV, discerning the signal from the noise is difficult without a moving source to induce the modulation. A rotating wheel is currently being used as the moving source but its configuration is impractical and has cumbersome placement inside the current frangible joint test cell. As a way to combat this problem and verify a satisfactory signal-to-noise ratio, a reflective moving crystal piezo will be used to modulate a beat frequency, and an absorptive target will be used to block the signal in order to determine any back reflection coming from the probe and discern the true signal-to noise ratio. The piezo will be mounted and inserted onto the test table on an extendable telescopic antenna grounded by a magnetic base in the test zone. This piezo configuration will be more compatible within the test zone and allow for easy removal of the disk following acceptable signal verification and prior to frangible joint tests.Additionally, topics of what was learned and smaller tasks given at White Sands Test Facility (WSTF) will be discussed. All statements in this paper are newly gained knowledge of what I have learned, observed, and have done while at WSTF.

Ellis, Tayera↗
DOE OSTI2020

Liquid-Cooled Heat Sink Optimization for Thermal Imbalance Mitigation in Wide-Bandgap Power Modules

Power semiconductor die layout in substrates used in power modules is generally optimized for minimum electrical parasitics (e.g., stray inductance) by considering the minimum spacing between dies for thermal decoupling. The layout assumes sufficient heat spreading and transfer from dies to the cooling structure. For module designs using a direct substrate cooling method, the base plate is removed, leading to a steady-state thermal asymmetry in the power module due to insufficient heat spreading/transfer. This causes significant temperature differences among the devices. Such unintentional thermal asymmetries can lead to undesirable asymmetries in power conversion among semiconductor devices, which impact reliability. This article proposes a thermal imbalance mitigation method that uses evolutionary optimized liquid-cooled heat sinks to improve the thermal loading among devices.

Sahu, Raj↗
DOE OSTI2022

A Reliable, Cost-Effective Transformerless Medium-Voltage Inverter for Grid Integration of Combined Solar and Energy Storage

The goal of this project is to utilize an innovative holistic power electronic inverter design approach, which can leverage best-in-class silicon carbide (SiC) power modules, novel multi-level power electronic circuits, high frequency transformers, switching sequence based control and co-designed electro-thermal management methods, to realize a 300 kW transformerless medium-voltage (MV) inverter system. The system cost of the inverter is considered as a primary design objective alongside high power density, efficiency, low electromagnetic interference (EMI) and long lifespan. This design-oriented research activity, especially the proposed multi-objective optimization approach, will have broad impacts in holistic power electronic system design methods and in technologies that can be commercialized into a wide variety of wide bandgap power electronic applications.

14 SOLAR ENERGY↗
NASA NTRS1979

Reliable inverter systems

Base driver with common-load-current feedback protects paralleled inverter systems from open or short circuits. Circuit eliminates total system oscillation that can occur in conventional inverters because of open circuit in primary transformer winding. Common feedback signal produced by functioning modules forces operating frequency of failed module to coincide with clock drive so module resumes normal operating frequency in spite of open circuit.

Nagano, S.↗
DOE OSTI2012

The application of Plant Reliability Data Information System (PRINS) to CANDU reactor

As risk-informed applications (RIAs) are actively implanted in the nuclear industry, an issue associated with technical adequacy of Probabilistic Safety Assessment (PSA) arises in its modeling and data sourcing. In Korea, PSA for all Korean NPPs has been completed and KHNP(Korea Hydro and Nuclear Power Plant Company) developed the database called the Plant Reliability Data Information System (PRinS). It has several characteristics that distinguish it from other database system such as NPRDs (INPO,1994), PRIS (IAEA), and SRDF (EdF). This database has the function of systematic data management such as automatic data-gathering, periodic data deposition and updating, statistical analysis including Bayesian method, and trend analysis of failure rate or unavailability. In recent PSA for CANDU reactor, the component failure data of EPRI ALWR URD and Component Reliability Database were preferentially used as generic data set. The error factor for most component failure data was estimated by using the information NUREG/CR-4550 and NUREG/CR-4639. Also, annual trend analysis was performed for the functional losses of components using the statistical analysis and chart module of PRinS. Furthermore, the database has been updated regularly and maintained as a living program to reflect the current status. This paper presents the failure data analysis using PRinS which provides Bayesian analysis on main components in the CANDU reactor. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Design, Fabrication and On-Sun Performance Evaluation of SiC Receiver Feature Specimens for CST Applications Using Additively Manufactured SiC Materials

Increasing operating temperatures of solar receivers is paramount to the efficiency of concentrated solar thermal (CST) and solar power (CSP) systems. Successful development of CST systems to generate heat for industrial applications requires significant increase in temperature capability and techno-economically viability of the receiver systems. Supported by an award from the Solar Technology Office (SETO), US Department of Energy (DOE), GE Aerospace Research in collaboration with Heliogen Holdings Inc and Sandia National Lab, is engaged in the development of ultra-High Operating Temperature SiC-matrix Solar Thermal Air Receiver (HOTSSTAR) enabled by additive manufacturing. The program objective is to demonstrate SiC receiver with air exit temperatures up to 1100 oC and high thermal efficiencies. We report design, fabrication and on-sun test results of SiC components of a prototype 50kW (thermal) HOTSSTAR module. The receiver module architecture is based on a radial airflow design and consists of a series of radial SiC receiver sectors organized around a SiC center absorber. The SiC components are fabricated using binder-jet printed SiC followed by melt-infiltration reaction bonding process. To enhance the reliability and to minimize the risk of cracking damage of SiC test articles in thermal gradient and thermal shock environment of the application, the components were laminated with GE’s MI SiC-SiC CMC. Following extensive design and lab test analyses, selected SiC component designs are tested at Heliogen Lancaster Solar field under highly concentrated solar fluxes around 2000 suns to assess the thermal performance characteristics under realistic field conditions. We report on the test results and compare the thermal performances of different HOTSSTAR SiC absorbers. Finally, we discuss fabrication and initial assembly of a 50kW prototype test module in preparation of on-sun field tests to assess the performance of our final design.

CST, CSP, high temperature, air receiver, SiC, add↗
DOE OSTI2018

Advancing the Fork detector for quantitative spent nuclear fuel verification

The Fork detector is widely used by the safeguards inspectorate of the European Atomic Energy Community (EURATOM) and the International Atomic Energy Agency (IAEA) to verify spent nuclear fuel. Fork measurements are routinely performed for safeguards prior to dry storage cask loading. Additionally, spent fuel verification will be required at the facilities where encapsulation is performed for acceptance in the final repositories planned in Sweden and Finland. The use of the Fork detector as a quantitative instrument has not been prevalent due to the complexity of correlating the measured neutron and gamma ray signals with fuel inventories and operator declarations. A spent fuel data analysis module based on the ORIGEN burnup code was recently implemented to provide automated real-time analysis of Fork detector data. This module allows quantitative predictions of expected neutron count rates and gamma units as measured by the Fork detectors using safeguards declarations and available reactor operating data. This study describes field testing of the Fork data analysis module using data acquired from 339 assemblies measured during routine dry cask loading inspection campaigns in Europe. Assemblies include both uranium oxide and mixed-oxide fuel assemblies. More recent measurements of 50 spent fuel assemblies at the Swedish Central Interim Storage Facility for Spent Nuclear Fuel are also analyzed. An evaluation of uncertainties in the Fork measurement data is performed to quantify the ability of the data analysis module to verify operator declarations and to develop quantitative go/no-go criteria for safeguards verification measurements during cask loading or encapsulation operations. The goal of this approach is to provide safeguards inspectors with reliable real-time data analysis tools to rapidly identify discrepancies in operator declarations and to detect potential partial defects in spent fuel assemblies with improved reliability and minimal false positive alarms. Finally, the results are summarized, and sources and magnitudes of uncertainties are identified, and the impact of analysis uncertainties on the ability to confirm operator declarations is quantified.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2017

Development of in-situ high-voltage and high-temperature stressing capability on atomic force microscopy platform

Reliability has become an increasingly important issue as photovoltaic technologies mature. However, researching reliability at the nanometer scale is in its infancy; in particular, in-situ studies have not been reported to date. Here, to investigate potential-induced degradation (PID) of solar cell modules, we have developed an in-situ stressing capability with applied high voltage (HV) and high temperature (HT) on an atomic force microscopy (AFM) platform. We designed a sample holder to simultaneously accommodate 1000-V HV and 200 degrees C HT stressing. Three technical challenges have been overcome along with the development: thermal drift at HT, HV interference with measurement, and arc discharge caused by HV. We demonstrated no observable measurement artifact under the stress conditions. Based on our in-situ stressing AFM, Kelvin probe force microscopy potential imaging revealed the evolution of electrical potential across the junction along with the PID stressing time, which provides vital information to further study the PID mechanism.

14 SOLAR ENERGY↗
DOE OSTI2015

A progressively reduced pretension method to fabricate Bradbury-Nielsen gates with uniform tension

A Bradbury-Nielsen gate (BNG) is often used to modulate ion beams. It consists of two interleaved and electrically isolated sets of wires with uniform tension, which ideally keep parallel, equidistant, and coplanar over a wide temperature range, making the BNG reliable and robust. We have previously analyzed the non-uniformity problem of wire tensions with sequentially winding method and developed a template-based transfer method to solve this problem. In this paper, we introduced a progressively reduced pretension method, which allows directly and sequentially fixing wires onto the substrate without using a template. Theoretical analysis shows that by applying proper pretension to each wire when fixing it, the final wire tensions of all wires can be uniform. The algorithm and flowchart to calculate the pretension sequence are given, and the fabrication process is introduced in detail. Pretensions are generated by weight combination with a weaving device. A BNG with stainless steel wire and a printed circuit board substrate is constructed with this method. The non-uniformity of the final wire tensions is less than 2.5% in theory. The BNG is successfully employed in our ion mobility spectrometer, and the measured resolution is 33.5 at a gate opening time of 350 μs. Compared to the template-based method, this method is simpler, faster, and more flexible with comparable production quality when manufacturing BNGs with different configurations.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2022

Artificial Intelligence for Power Electronics in Electric Vehicles: Challenges and Opportunities

We report progress in the field of power electronics within electric vehicles has generally been driven by conventional engineering design principles and experiential learning. Power electronics is inherently a multidomain field where semiconductor physics and electrical, thermal, and mechanical design knowledge converge to achieve a practical realization of desired targets in the form of conversion efficiency, power density, and reliability. Due to the promising nature of artificial intelligence in delivering rapid results, engineers are starting to explore the ways in which it can contribute to making power electronics more compact and reliable. Here, we conduct a brief review of the foray of artificial intelligence in three distinct subtechnologies within a power electronics system in the context of electric vehicles: semiconductor devices, power electronics module design and prognostics, and thermal management design. The intent is not to report an exhaustive literature review, but to identify the state of the art and opportunities for artificial intelligence to play a meaningful role in power electronics design from a mechanical and thermal standpoint, as well as to discuss a few promising future research directions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2026

V-HAMSTeR v1.0.0

V-HAMSTeR is a bioinformatics software tool designed to predict the hosts of viruses directly from genomic sequences. It can be used by researchers to predict animal, prokaryotic, plant, protist or fungal viral hosts including viruses that may be fragmented or discovered in environmental metagenomic datasets. Features & Uses: The software employs a novel dual-stream deep learning architecture that dynamically fuses implicit sequence embeddings from a genomic foundation model with 13 explicit, handcrafted biological features (e.g., coding density and strand switch rates). To ensure maximum reliability, V=HAMSTeR deploys a 5-fold deep ensemble calibrated via Joint Temperature Scaling, providing users with statistically rigorous confidence probabilities. It also features an automated sequence chunking and mean-pooling module to seamlessly process variable-length contigs. Advantages Over Similar Technologies: Existing tools (e.g., IPEV, RNAVirHost) typically rely on either basic k-mers or isolated neural networks. V-HAMSTeR's hybrid architecture captures both broad genomic context and specific biological motifs that standalone foundation models often miss. Furthermore, unlike competitor tools that struggle with incomplete data or exhibit extreme overconfidence, V-HAMSTeR is explicitly benchmarked and mathematically calibrated for fragmented assemblies (1kb–10kb). This makes it uniquely robust, accurate, and trustworthy for the messy reality of real-world environmental viromics.

Grigson, Susie [Lawrence Berkeley National Laborat↗
NASA NTRS1980

Optical-communication systems for deep-space applications

The feasibility of using optical communication systems for data telemetry from deep space vehicles to Earth based receivers is evaluated. Performance analysis shows that practical, photon counting optical systems can transmit data reliably at 30 to 40 dB high rates than existing RF systems, or can be used to extend the communication range by 15 to 20 dB. The advantages of pulse-position modulation (PPM) formats are discussed, and photon counting receiver structures designed for PPM decoding are described. The effects of background interference and weather on receiver performance are evaluated. Some consideration is given to tracking and beam pointing operations, since system performance ultimately depends on the accuracy to which these operations can be carried out. An example of a tracking and pointing system utilizing an optical uplink beacon is presented, and it is shown that microradian beam pointing is within the capabilities of state-of-the-art technology. Recommendations for future theoretical studies and component development programs are presented.

Vilnrotter, V. A.↗
NASA NTRS1991

Advanced technologies for rocket single-stage-to-orbit vehicles

A single-stage-to-orbit vertical takeoff/horizontal landing rocket vehicle was studied to determine the benefits of advanced technology. Advanced technologies that were included in the study were variable mixture ratio oxygen/hydrogen rocket engines and materials, structures, and subsystem technologies currently being developed in the National Aero-Space Plane Program. The application of advanced technology results in an 85 percent reduction in vehicle dry weight. With advanced materials, an external thermal protection system, like the Space Shuttle tiles, was not required. Compared to an all-airbreathing horizontal takeoff/horizontal landing vehicle using the same advanced technologies and mission requirements, the rocket vehicle is lighter in dry weight and has fewer subsystems. To increase reliability and safety, operational features were included in the rocket vehicle-robust subsystems, 5 percent additional margin, no slush hydrogen, fail-operational with an engine out, and a crew escape module. The resulting vehicle grew in dry weight and was still lower in dry weight than the airbreathing vehicle.

Wilhite, Alan W.↗
NASA NTRS1992

A membrane-based subsystem for water-vapor recovery from plant-growth chambers

Bioregenerative systems--life-support systems to regenerate oxygen, food, and water--are the key to establishing man's permanent presence in space. NASA is investigating the use of plant-growth chambers (PGC's) for space missions and for bases on the moon and Mars. PGC's serve several important purposes, including the following: (1) oxygen and food production; (2) carbon-dioxide removal; and (3) water purification and reuse. The key to the successful development of PGC's is a system to recover and reuse the water vapor that is transpired by the leaves of the growing plants. In this program we propose to develop a simple, reliable, membrane-based system that allows the recovery, purification, and reuse of the transpired water vapor through control of temperature and humidity levels in the PGC. This system has characteristics that make it ideally suited to use in space: (1) minimal power requirements; (2) small volume and mass; (3) simplicity; (4) reliability; and (5) versatility. In Phase 1 we will do the following: (1) develop an accurate, predictive model of our temperature- and humidity-control system, based on parametric tests of membrane modules; and (2) use this model to design systems for selected PGC's. In Phase 2, we will seek to design, fabricate, test, and deliver a breadboard unit to NASA for testing on a PGC.

Ray, R. J.↗
NASA NTRS1993

Hubble Space Telescope EVA Power Ratchet Tool redesign

The Power Ratchet Tool (PRT) is a self contained, power-driven, 3/8 inch drive ratchet wrench which will be used by astronauts during Extravehicular Activities (EVA). This battery-powered tool is controlled by a dedicated electonic controller. The PRT was flown during the Hubble Space Telescope (HST) Deployment Mission STS-31 to deploy the solar arrays if the automatic mechanisms failed. The PRT is currently intended for use during the first HST Servicing Mission STS-61 as a general purpose power tool. The PRT consists of three major components; the wrench, the controller, and the battery module. Fourteen discrete combinations of torque, turns, and speed may be programmed into the controller before the EVA. The crewmember selects the desired parameter profile by a switch mounted on the controller. The tool may also be used in the manual mode as a non-powered ratchet wrench. The power is provided by a silver-zinc battery module, which fits into the controller and is replaceable during an EVA. The original PRT did not meet the design specification of torque output and hours of operation. To increase efficiency and reliability the PRT underwent a redesign effort. The majority of this effort focused on the wrench. The original PRT drive train consisted of a low torque, high speed brushless DC motor, a face gear set, and a planocentric gear assembly. The total gear reduction was 300:1. The new PRT wrench consists of a low speed, high torque brushless DC motor, two planetary gear sets and a bevel gear set. The total gear reduction is now 75:1. A spline clutch has also been added to disengage the drive train in the manual mode. The design changes to the controller will consist of only those modifications necessary to accomodate the redesigned wrench. The battery design will be unaffected.

Richards, Paul W.↗
NASA NTRS1999

Validation of Landsat-7 ETM+ MEM Thermal Improvement in Thermal Vacuum Tests and in Flight Due to Lower Louver Set Points

The Enhanced Thematic Mapper Plus (ETM+) Main Electronics Module (MEM) power supply heat sink temperature is critical to the Landsat-7 mission. It is strongly dependent on the thermal louver design. A lower power supply heat sink temperature increases the reliability of the MEM, and reduces the risk of over heating and thermal shut-down. After the power supply failures in ETM+ instrument thermal vacuum tests #1 and #2, the author performed detailed thermal analyses of the MEM, and proposed to reduce the louver set-points by 7C. At the 1998 Intersociety Energy Conversion Engineering Conference (IECEC), the author presented a paper that included results of thermal analysis of the MEM. It showed that a 70C reduction of the louver set points could reduce the maximum power supply heat sink temperature in thermal vacuum test and in flight to below 20"C in the cooler outgas mode and in the nominal imaging mode, and has no significant impact on the standby heater duty cycle. It also showed that the effect of Earth infrared and albedo on the power supply heat sink temperature is small. The louver set point reduction was implemented in June 1998, just prior to ETM+ thermal vacuum test #3. Results of the thermal vacuum tests, and temperature data in flight validate the MEM thermal performance improvement due to the 70C reduction of the louver set points.

Choi, Michael K.↗
NASA NTRS2010

Optimization Testbed Cometboards Extended into Stochastic Domain

COMparative Evaluation Testbed of Optimization and Analysis Routines for the Design of Structures (CometBoards) is a multidisciplinary design optimization software. It was originally developed for deterministic calculation. It has now been extended into the stochastic domain for structural design problems. For deterministic problems, CometBoards is introduced through its subproblem solution strategy as well as the approximation concept in optimization. In the stochastic domain, a design is formulated as a function of the risk or reliability. Optimum solution including the weight of a structure, is also obtained as a function of reliability. Weight versus reliability traced out an inverted-S-shaped graph. The center of the graph corresponded to 50 percent probability of success, or one failure in two samples. A heavy design with weight approaching infinity could be produced for a near-zero rate of failure that corresponded to unity for reliability. Weight can be reduced to a small value for the most failure-prone design with a compromised reliability approaching zero. The stochastic design optimization (SDO) capability for an industrial problem was obtained by combining three codes: MSC/Nastran code was the deterministic analysis tool, fast probabilistic integrator, or the FPI module of the NESSUS software, was the probabilistic calculator, and CometBoards became the optimizer. The SDO capability requires a finite element structural model, a material model, a load model, and a design model. The stochastic optimization concept is illustrated considering an academic example and a real-life airframe component made of metallic and composite materials.

Patnaik, Surya N.↗