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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

NASA Facts: AERoBOND Project

Sustainability of the commercial air travel industry requires new aircraft with ultra-efficient structures and designs, which will depend largely on lightweight polymer composites and new assembly methods. Manufacturers of commercial transport aircraft are compelled to install thousands of redundant fasteners into bonded joints to prevent failures due to unpredictable weak bonds. The Adhesive-Free Bonding of Complex Composites (AERoBOND) process enables re-flow of matrix resin during assembly to eliminate the material discontinuity at the interface, thereby eliminating the dependence of mechanical performance on interfacial adhesion.

Frank Louis Palmieri↗
DOE OSTI2021

High-Temperature Multi-Process Sensor Development and Demonstration at a Full-scale PC Combustion System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution of wall conditions in utility boilers. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of a coal-fired utility boiler in this project but can be applied to many other industries and applications as well. The new sensor design, leveraging the existing electrochemical noise-based monitoring system, is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data can be transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, five mMPMS were installed at a full-scale pulverized coal-fired plant, Basin Electric Power Cooperative’s Leland Olds Unit 1. The systems were demonstrated over a 6-week period during typical operation. Sensor measurements of deposit thickness were validated during the demonstration and subsequently leveraged to determine sensor-based boiler cleaning strategies. These strategies have the benefit of reduced thermal stresses on boiler tubes from over-cleaning and improved boiler water management. At the end of the project, continued development of the sensor technology was carried out at PacifiCorp’s Hunter Station. REI leveraged the permanent installation of the mMPMS in Unit 3 made possible by DOE funding on a separate program. The work at Hunter Plant focused on application of machine learning and artificial intelligence-based models for integration of sensor signals into control and optimization of Hunter Unit 3 processes.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2021

High-Temperature Multi-Process Sensor Development and Demonstration at a Full-scale PC Combustion System

The main objective of this research program is to design, manufacture, and demonstrate a miniaturized, multi-process, monitoring system (mMPMS) for boiler condition management and easy system deployment to obtain a higher spatial resolution. This system will facilitate a Condition-Based Maintenance (CBM) philosophy that actively monitors the health of assets to predict and prevent failures and maximize availability and generating capacity at a reduced cost. CBM systems can provide boiler data that the advanced process control (APC) system can utilize for plant performance optimization, which is increasingly relevant as coal power plants shift from predominantly base-load operation to predominantly transient operation involving large load swings. The mMPMS is based on an electrochemical sensor that provides a real-time indication of the risk of damage to key locations in the radiant or convective section of a coal-fired boiler such as metal loss rates, heat flux, metal surface temperature, and deposit thickness. These indications can be utilized to optimize boiler performance as well as improve boiler availability in conjunction with corresponding operating conditions. This monitoring system was developed and tested in the high-temperature regions of coal-fired utility boilers in this project but can be applied to many other industries and applications as well. This project leveraged the existing electrochemical noise-based monitoring system and the new sensor design is small enough to be installed through the webbing of the waterwalls without the need for long shut-downs to bend tubes and to make it feasible to obtain high spatial resolution in the boiler. Data is transferred to the plant distributed control system (DCS) and any other control system. The sensor body that houses the sensor assembly was designed to ensure good conductive contact with boiler tubes to ensure the sensor is held at an identical temperature to the tube surface temperature. The data acquisition and signal conditioning modules were redesigned into a small footprint with optimized cooling of the module. System software was developed specifically for the new signal conditioning module and is compatible with plant PLCs. After the preliminary testing at a pilot-scale facility, the three mMPMS were installed at a full-scale pulverized coal-fired plant, PacifiCorp’s Hunter 3. The systems were demonstrated over 20,000 hours at the plant during regular operation. Also, the sensor data was fed to the plant’s advanced process control system to evaluate the corrosion control by the operation changes and utilized to understand the impacts of load cycling with different ramping up and down speeds. At the end of the project, the systems were converted to the permanent installation at the power plant to be used with the advanced process control system installed at the plant.

Advanced Sensors, Corrosion, Ash Deposition, Optim↗
DOE OSTI2021

Evidence Theory Representations for Properties Associated With Weak Link/Strong Link Systems, Part 3: Margins for Failure Time and Failure Temperature

The use of evidence theory and associated cumulative plausibility functions (CPFs), cumulative belief functions (CBFs), cumulative distribution functions (CDFs), complementary cumulative plausibility functions (CCPFs), complementary cumulative belief functions (CCBFs), and complementary cumulative distribution functions (CCDFs) in the analysis of time and temperature margins associated with loss of assured safety (LOAS) for one weak link (WL)/two strong link (SL) systems is illustrated. Article content includes cumulative and complementary cumulative belief, plausibility, and probability for (i) SL/WL failure time margins defined by (time at which SL failure potentially causes LOAS) – (time at which WL failure potentially prevents LOAS), (ii) SL/WL failure temperature margins defined by (the temperature at which SL failure potentially causes LOAS) – (the temperature at which WL failure potentially prevents LOAS), and (iii) SL/SL failure temperature margins defined by (the temperature at which SL failure potentially causes LOAS) – (the temperature of SL whose failure potentially causes LOAS at the time at which WL failure potentially prevents LOAS).

42 ENGINEERING↗
NASA NTRS1994

Environmental testing to prevent on-orbit TDRS failures

Can improved environmental testing prevent on-orbit component failures such as those experienced in the Tracking and Data Relay Satellite (TDRS) constellation? TDRS communications have been available to user spacecraft continuously for over 11 years, during which the five TDRS's placed in orbit have demonstrated their redundancies and robustness by surviving 26 component failures. Nevertheless, additional environmental testing prior to launch could prevent the occurrence of some types of failures, and could help to maintain communication services. Specific testing challenges involve traveling wave tube assemblies (TWTA's) whose lives may decrease with on-off cycling, and heaters that are subject to thermal cycles. The development of test conditions and procedures should account for known thermal variations. Testing may also have the potential to prevent failures in which components such as diplexers have had their lives dramatically shortened because of particle migration in a weightless environment. Reliability modeling could be used to select additional components that could benefit from special testing, but experience shows that this approach has serious limitations. Through knowledge of on-orbit experience, and with advances in testing, communication satellite programs might avoid the occurrence of some types of failures, and extend future spacecraft longevity beyond the current TDRS design life of ten years. However, determining which components to test, and how must testing to do, remain problematical.

Cutler, Robert M.↗
NASA NTRS1992

Accelerometer method and apparatus for integral display and control functions

Vibration analysis has been used for years to provide a determination of the proper functioning of different types of machinery, including rotating machinery and rocket engines. A determination of a malfunction, if detected at a relatively early stage in its development, will allow changes in operating mode or a sequenced shutdown of the machinery prior to a total failure. Such preventative measures result in less extensive and/or less expensive repairs, and can also prevent a sometimes catastrophic failure of equipment. Standard vibration analyzers are generally rather complex, expensive, and of limited portability. They also usually result in displays and controls being located remotely from the machinery being monitored. Consequently, a need exists for improvements in accelerometer electronic display and control functions which are more suitable for operation directly on machines and which are not so expensive and complex. The invention includes methods and apparatus for detecting mechanical vibrations and outputting a signal in response thereto. The apparatus includes an accelerometer package having integral display and control functions. The accelerometer package is suitable for mounting upon the machinery to be monitored. Display circuitry provides signals to a bar graph display which may be used to monitor machine condition over a period of time. Control switches may be set which correspond to elements in the bar graph to provide an alert if vibration signals increase over the selected trip point. The circuitry is shock mounted within the accelerometer housing. The method provides for outputting a broadband analog accelerometer signal, integrating this signal to produce a velocity signal, integrating and calibrating the velocity signal before application to a display driver, and selecting a trip point at which a digitally compatible output signal is generated. The benefits of a vibration recording and monitoring system with controls and displays readily mountable on the machinery being monitored and having capabilities described will be appreciated by those working in the art.

Bozeman, Richard J., Jr.↗
DOE OSTI2023

Startup process for a dual active bridge converter to prevent over-voltage failure and thermal run-away

A system and method for controlling a dual active bridge based DC/DC converter. A controller implements a startup control scheme and DC bus pre-charge routine to prevent damage to the converter upon startup. During startup of the converter, the startup control process can be used to prevent excessive phase-shift and the DC bus pre-charge routine adjusts the pulse width modulated duty cycle by increasing the dead time between signals, resulting in a decreased DC bus capacitor.

Singh, Braj K.↗
NASA NTRS2002

A Framework for Creating a Function-based Design Tool for Failure Mode Identification

Knowledge of potential failure modes during design is critical for prevention of failures. Currently industries use procedures such as Failure Modes and Effects Analysis (FMEA), Fault Tree analysis, or Failure Modes, Effects and Criticality analysis (FMECA), as well as knowledge and experience, to determine potential failure modes. When new products are being developed there is often a lack of sufficient knowledge of potential failure mode and/or a lack of sufficient experience to identify all failure modes. This gives rise to a situation in which engineers are unable to extract maximum benefits from the above procedures. This work describes a function-based failure identification methodology, which would act as a storehouse of information and experience, providing useful information about the potential failure modes for the design under consideration, as well as enhancing the usefulness of procedures like FMEA. As an example, the method is applied to fifteen products and the benefits are illustrated.

Arunajadai, Srikesh G.↗
NASA NTRS1983

Energy absorption of composite materials

Results of a study on the energy absorption characteristics of selected composite material systems are presented and the results compared with aluminum. Composite compression tube specimens were fabricated with both tape and woven fabric prepreg using graphite/epoxy (Gr/E), Kevlar (TM)/epoxy (K/E) and glass/epoxy (Gl/E). Chamfering and notching one end of the composite tube specimen reduced the peak load at initial failure without altering the sustained crushing load, and prevented catastrophic failure. Static compression and vertical impact tests were performed on 128 tubes. The results varied significantly as a function of material type and ply orientation. In general, the Gr/E tubes absorbed more energy than the Gl/E or K/E tubes for the same ply orientation. The 0/ + or - 15 Gr/E tubes absorbed more energy than the aluminum tubes. Gr/E and Gl/E tubes failed in a brittle mode and had negligible post crushing integrity, whereas the K/E tubes failed in an accordian buckling mode similar to the aluminum tubes. The energy absorption and post crushing integrity of hybrid composite tubes were not significantly better than that of the single material tubes.

Farley, G. L.↗
DOE OSTI2023

Monte Carlo Analysis of Coolant Stream Impurity Gamma Emissions in Gas-Cooled Fast Reactors

It is well established that a rapid increase in the concentration of fission products in the reactor coolant stream can serve as an early indication of fuel failure. We use Monte Carlo simulations to investigate the feasibility of using several gamma detectors as diagnostic equipment to monitor the presence of major fission product isotopes in high-temperature gas-cooled reactor (HTGR) coolant streams for early detection of fuel failure and therefore the prevention of fuel failure conditions. Herein we model the response of high-purity germanium (HPGe), CdZnTe, NaI(Tl), and LaBr 3 (Ce) detectors of typical commercial sizes to the gamma emissions from nuclides expected to be found within the coolant stream of the Versatile Test Reactor (VTR) under development by the U.S. Department of Energy. The results indicate that for the 233- and 250-keV gamma rays from 133 Xe and 135 Xe, respectively, the 3σ detection criterion is met in under 1 min using a single HPGe detector. Changes in other spectral lines associated with Xe nuclides are detected within 1 h regardless of the choice of detector.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2004

NASCAP Modeling of GEO Satellites--Spacecraft Charging is Back!

During the last few years of Solar Minimum, GEO spacecraft charging design practices may have become lax because of paucity of spacecraft charging events. Unfortunately, this has also been the time of great changes in spacecraft design, because of the new emphases on higher power arrays and lower costs. Also unfortunate is the fact that spacecraft charging may lead to failures of solar array strings, panels, or entire spacecraft. One way to prevent satellite failures die to spacecraft charging events is to simulate the effects with a charging code, such as the venerable NASCAP/GEO code. We will discuss the use of NASCAP on the ACTS satellite as well as a newer application dealing with typical recent spacecraft charging anomalies.

Chock, R.↗
DOE OSTI2024

Mitigating commutation failures in HVDC systems with SFCL deployment

Commutation failures represent a prevalent issue encountered in line-commutated-converter high voltage direct current (LCC-HVDC) systems. As the widespread deployment of HVDC systems continues, the risk associated with commutation failures increases, posing a growing threat to power grids due to their potential to trigger severe consequences, including cascading failures and widespread blackouts. This research paper aims to address the significant issue of commutation failure within direct current (DC) systems through advocating for the use of resistive-type Superconducting Fault Current Limiters (R-SFCLs). To substantiate the efficacy of this proposed strategy, an array of simulations are executed using the PSCAD/EMTDC software. This comprehensive study investigates the performance characteristics of R-SFCLs configured with varying resistance values, scrutinizing their response under diverse fault resistance scenarios and distinct fault initiation times within the LCC-HVDC system. The outcomes of these simulations are that SFCLs confer significant advantages for mitigating commutation failures, surpassing traditional mitigation methods in terms of effectiveness. Consequently, SFCLs emerge as an optimal solution to prevent commutation failures in the HVDC systems.

Commutation failure↗
DOE OSTI2025

A survey on degradation modeling, prognosis, and prognostics-driven maintenance in wind energy systems

Wind energy generation proliferated over the past decades, introducing unique challenges and opportunities for failure prediction, operation and maintenance. Decision-makers are continuously looking into new methods to infer failure mechanisms and behaviors of wind turbine components to detect and intervene in the failures before they happen. Evidently, degradation modeling and prognosis become engaging topics for researchers and practitioners to prevent catastrophic failures. Prognostics-driven approaches predict the time of failure for the components (e.g., predicting remaining useful life), which provides significant insights for scheduling of operations and maintenance activities. Integrating these prognostics-driven insights into wind farm operations and maintenance presents a substantial challenge, demanding careful consideration of numerous factors such as accessibility, crew routing, and spare part logistics. This study provides state-of-the-art review for degradation modeling, prognosis, and prognostics-driven maintenance techniques for wind energy systems. The discussed techniques align with the United Nations' sustainable development goals, in particular Goal 7 (Affordable and Clean Energy), by enhancing effectiveness and sustainability of wind energy operations. This work also showcases open research questions related to degradation modeling, prognosis, and prognostics-driven maintenance.

Altinpulluk, Nur Banu↗
NASA NTRS2008

PH and Electrochemical Responsive Materials for Corrosion Smart Coating Applications

Corrosion is a costly issue for military operations and civil industries. While most corrosion initiates from localized corrosion form, such as pitting, failure directly caused by localized corrosion is the most dangerous kind, because it is difficult to anticipate and prevent, occurs very suddenly and can be catastrophic. One way of preventing these failures is with a coating that can detect and heal localized corrosion. pH and other electrochemical changes are often associated with localized corrosion, so it is expected that materials that are pH or otherwise electrochemical responsive can be used to detect and control corrosion. This paper will review various pH and electrochemical responsive materials and their potential applications in corrosion smart coatings. Current research results in this field will also be reported.

Li, Wenyan↗
NASA NTRS1974

Design of mechanical components for long-term performance

Review of the results of a NASA program designed to study advanced techniques for determining the long-term performance of rocket engine components. Aging and operational degradation mechanisms of metal valve seats are identified. Characterization of metal valve seat surfaces by optical signature analysis is described. The results of the development of a long-life 'zero leakage' metal valve seal designed to avoid failure by contamination, stress/strain, fatigue, and the deterioration of the surface by wear is reported. An analysis of a specific seat design showed that material strain prevention along all axes would prevent these failures. The design provided for refurbishment of the sealing surfaces during each valve cycle, thereby preventing cumulative surface damage.

Salvinski, R. J.↗