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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 NTRS1989

KOH concentration effect on the cycle life of nickel-hydrogen cells. 4: Results of failure analyse

Effects of KOH concentrations on failure modes and mechanisms of nickel-hydrogen cells were studied using long cycled boiler plate cells containing electrolytes of various KOH concentrations ranging 21 to 36 percent. Life of these cells were up to 40,000 cycles in an accelerated low earth orbit (LEO) cycle regime at 80 percent depth of discharge. An interim life test results were reported earlier in J. Power Sources, 22, 213-220, 1988. The results of final life test, end-of-life cell performance, and teardown analyses are discussed. These teardown analyses included visual observations, measurements of nickel electrode capacity in an electrolyte-flooded cell, dimensional changes of cell components, SEM studies on cell cross section, BET surface area and pore volume distribution in cycled nickel electrodes, and chemical analyses. Cycle life of a nickel-hydrogen cell was improved tremendously as KOH concentration was decreased from 36 to 31 percent and from 31 to 26 percent while effect of further concentration decrease was complicated as described in our earlier report. Failure mode of high concentration (31 to 36 percent) cells was gradual capacity decrease, while that of low concentration (21 to 26 percent) cells was mainly formation of a soft short. Long cycled (25,000 to 40,000 cycles) nickel electrodes were expanded more than 50 percent of the initial value, but no correlation was found between this expansion and measured capacity. All electrodes cycled in low concentration (21 to 26 percent) cells had higher capacity than those cycled in high concentration (31 to 36 percent) cells.

Lim, H. S.↗
NASA NTRS1985

Challenges in the development of the orbiter atmosphere revitalization subsystem

The space shuttle orbiter atmospheric revitalization subsystem provides thermal and contaminant control as well as total- and oxygen partial-pressure control of the environment within the orbiter crew cabin. Challenges that occurred during the development of this subsystem for the space shuttle orbiter are described. The design of the rotating hardware elements of the system (pumps, fans, etc.) required significant development to meet the requirements of long service life, maintainability, and high cycle-fatigue life. As a result, a stringent development program, particularly in the areas of bearing life and heat dissipation, was required. Another area requiring significant development was cabin humidity control and condensate collection.

Prince, R. N.↗
NASA NTRS1990

Development and fabrication of structural components for a scramjet engine

A program broadly directed toward design and development of long-life (100 hours and 1,000 cycles with a goal of 1,000 hours and 10,000 cycles) hydrogen-cooled structures for application to scramjets is presented. Previous phases of the program resulted in an overall engine design and analytical and experimental characterization of selected candidate materials and concepts. The latter efforts indicated that the basic life goals for the program can be reached with available means. The main objective of this effort was an integrated, experimental evaluation of the results of the previous program phases. The fuel injection strut was selected for this purpose, including fabrication development and fabrication of a full-scale strut. Testing of the completed strut was to be performed in a NASA-Langley wind tunnel. In addition, conceptual designs were formulated for a heat transfer test unit and a flat panel structural test unit. Tooling and fabrication procedures required to fabricate the strut were developed, and fabrication and delivery to NASA of all strut components, including major subassemblies, were completed.

Buchmann, O. A.↗
NASA NTRS1999

Technology Maturity Towards Highly Reusable Space Transportation Goals

The National Aeronautics and Space Administration's (NASA) Advanced Space Transportation Program (ASTP) has advanced key propulsion and launch vehicle systems technologies towards enabling the concepts identified by the Highly Reusable Space Transportation (HRST) Study as having significant potential for reducing the cost of access to space. The Marshall Space Flight Center (MSFC) manages the ASTP for the NASA Aero-Space Technology Enterprise. The HRST Study was conducted from 1995 through 1997 to evaluated launch concepts with the potential to reduce launch cost to $100 to $200 per pound of payload to low Earth orbit in the 2016 to 2022 timeframe. The HRST represents a generation of launch vehicles beyond the Lockheed-Martin VentureStar concept with a goal of another factor of ten reduction in launch cost below the next generation Reusable Launch Vehicle. Several concepts were developed and evaluated during the initial HRST studies. At the completion of the concept development phase in 1997, four task forces were formed to integrate the results of the study. These task forces were System Concept Definition, Operations Assessment. Cost Assessment and Technology Assessment. The Operations Assessment task force published its final report in November 1998. The Operations Assessment task force evaluated both single stage to orbit (SSTO) and two-stage to orbit (TSTO) concepts. SSTO concepts included horizontal takeoff and horizontal landing, vertical takeoff and vertical landing and vertical takeoff and horizontal landing. Horizontally launched concepts including launch assist options. SSTO concepts included airbreathing and all rocket as well as combination propulsion systems. The Operations Assessment considered the significance of performance margin, flight rate capability, reliability, launch assist, design optimization and technology development. These studies serve as a guide for the ASTP to prioritize technology development towards future highly reusable launch systems. Although the ASTP supports the development of technology that is focused at a near term fully reusable launch vehicle, the core of the technology development is looking ahead to future generations of launch vehicles that will enable dramatic growth in civil and commercial space enterprise. The primary focus of the paper is to status the key enabling technologies including rocket based combined cycle (RBCC) propulsion, magnetic launch assist, long life, low weight rocket propulsion, integral hot structures. robust thermal protection systems and integrated vehicle health management. The ASTP technology roadmap is leading rapidly towards system demonstration and eventual future X vehicle flight demonstrations.

Lyles, Garry↗
NASA NTRS2008

Evaluation of Perfluoropolyether Lubricant Lifetime in the High Stress and High Stress-Cycle Regime for Mars Applications

The successful operation of long-life, highly loaded mechanisms used for planetary exploration or autonomous structures assembly will depend upon the ability to effectively lubricate rolling-element bearings. As new tools are developed (i.e., drill, abraders, robotic manipulators, etc.) that interact with their environment in a more direct manner, lubricants will be pushed past the bounds that current scientific literature has published. This paper details results from bearing lubrication lifetime testing performed in support of Honeybee Robotics development of the Mars Science Laboratory (MSL) Surface Removal Tool (SRT). This testing was done due to the lack of available data in research literature that is applicable to the lubrication regime the SRT bearings are being designed for. Based on the test results, the chosen bearing arrangement can be used for the SRT Grind Shaft bearings with the use of a Braycote Micronic 601EF grease-plate with a 10 vol% grease slurry fill (50/50 wt% Braycote Micronic 601EF and Brayco 815Z). This arrangement showed no signs of detrimental degradation over the course of the 3x life test. The purely grease-plated bearing ran at a consistently higher torque and showed signs of failure beginning at approximately 2.2 x 10(exp 7) revs (approximately 6.3 x 10(exp 7) stress-cycles) with a torque over-limit failure at approximately 4.5 x 10(exp 7) revs (approximately 1.3 x 10(exp 8) stress-cycles). Barring cold-start torque margin limitations, it is recommended that any long-life bearing application include some vol% grease-pack in addition to a standard grease-plate to reduce parasitic torque and increase bearing life. While these results are specific to a particular environment and loading condition, they demonstrate the extended capabilities of a commonly used flight lubricant outside of the range that is published in current research literature.

Herman, Jason↗
NASA NTRS1987

Long-Life Electrolyte for Nickel/Hydrogen Cells

Experiments show surprisingly substantial increase of cycle life of nickel/hydrogen cells when KOH concentration in electrolytes decreased from industry standard of 31 percent, while life decreased when concentration increased. Particularly important in view of prior recommendation to increase concentration to increase cell capacity. Benefit of increase of cycle life as concentration decreased is expected to outweigh reduction of capacity at beginning of life.

Lim, H. S.↗
NASA NTRS1984

In vitro seed to seed growth on clinostats

The effect of a long term micro-gravity environment on the life cycle of plants is unknown. Whether higher plants have evolved to a stage where removal or reduction of gravity is detrimental to plant life cycle and thus fatal to the plant species, is an unanswered question in space plants which were successfully grown through the various stages of their life cycle. Attempts to grow plants as a continuous integral process from seed to seed through one generation were successful until recently. Culture of plants through multiple generations was not accomplished in space nor in ground based studies. The effect of long term simulated weightlessness by growing consecutive generations of plants continuously on clinostats using the cruciferous plants, Arabidopsis thaliana (L.) Heyn. and Cardamine oligosperma Nutt. is being investigated.

Hoshizaki, T.↗
NASA NTRS2018

New Runtime Record Set for Free-Piston Stirling Machine

This article describes the recent progress GRC has made in the arena of long-life heat engines for power conversion. NASA has been interested in Stirling-cycle machines for power conversion since the 1970s. At that time, it was recognized that such a device could be designed to achieve long-life continuous operation with high reliability, by leveraging the free-piston configuration in favor of a kinematic engine. The free-piston variant eliminates the wear mechanisms associated with rolling-element bearings, piston rings, and connecting rods, typically found in kinematic Stirling engine designs. By restricting the moving components to linear motion only, there is no need to convert linear piston movement to rotating motion. With this, the moving components can be suspended within their cylinders by non-contacting bearings and seals can be effected with close clearances, also non-contacting. The use of a linear alternator attached directly to the piston enables direct conversion of heat, to mechanical, then to electrical energy, all in one hermetically sealed vessel, The electrical output only requires simple feedthroughs, and the complexity of sealed a rotating crankshaft is eliminated. In the free-piston variant, the displacer-to-piston phase is not implemented by a connection to a common rotating shaft. Instead, the pressure wave itself is used to drive the displacer. The displacer is designed to have a higher natural frequency of motion than the piston, which achieves a leading phase angle required for power production. The free-piston Stirling behaves like a spring-mass-damper system, with a forcing function created by the alternate heater and cooling of the working gas, and damping provided by the current flowing through the linear alternator. Two types of non-contacting bearings are available to designers: flexure and gas bearings. Flexure bearings consist of a spiral-cut disc of metal that has high radial stiffness but a deliberately engineering stiffness in the axial direction, to permit piston and displacer resonant motion. Gas bearings utilize a pressure source and precisely machined flow channels to provide a radial stiffness around the moving component. The pressure source can be supplied by the engine's pressure wave itself.

Oriti, Salvatore M.↗
NASA NTRS2022

Evolution of a Dark Vortex on Neptune with Transient Secondary Features

Dark spots on Neptune observed by Voyager and the Hubble Space Telescope are thought to be anticyclones with lifetimes of a few years, in contrast with very long-lived anticyclones in Jupiter and Saturn. The full life cycle of any Neptune dark spot has not been captured due to limited temporal coverage, but our Hubble observations of a recent feature, NDS-2018, provide the most complete long-term observational history of any dark vortex on Neptune. Past observations suggest some dark spots meet their demise by fading and dissipating without migrating meridionally. On the other hand, simulations predict a second pathway with equatorward migration and disruption. Our HST observations suggest NDS-2018 is following the second pathway.

Michael H Wong↗
NASA NTRS1993

Three-stage linear, split-Stirling cryocooler for 1 to 2K magnetic cold stage

A long-life, linear, high efficiency 8K split Stirling cycle cryocooler was designed, built, and tested. The refrigerator is designed for cooling a 50 mW, 1.5K magnetic cold stage. Dual opposed piston compressors are driven by moving-coil linear motors. The three stage expander, although not completed, is also driven by a linear motor and is designed to produce 1 SW at 60K, 4W at 16K, and 1.2W at 8K. The cold regenerator employs a parallel gap construction for high efficiency. The key technology areas addressed include warm and cold flexible suspension bearings and a new cold regenerator geometry for high efficiency at 8K.

Longsworth, R. C.↗
NASA NTRS1980

Effect of thermal cycling on ZrO2-Y2O3 thermal barrier coatings

A study was made of the comparative life of plasma sprayed ZrO2-Y2O3 thermal barrier coatings on NiCrAlY bond coats on Rene 41 in short (4 min) and long (57 min) thermal cycles to 1040 C in a 0.3 Mach flame. Short cycles greatly reduced the life of the ceramic coating in terms of time at temperature as compared to longer cycles. Appearance of the failed coating indicated compressive failure. Failure occurred at the bond coat-ceramic coat junction. At heating rates greater than 550 kw/sq m, the calculated coating detachment stress was in the range of literature values of coating adhesive/cohesive strength. Methods are discussed for decreasing the effect of high heating rate by avoiding compressive stress.

Mcdonald, G.↗
NASA NTRS2012

Woven TPS - A New Approach to TPS Design and Manufacturing

NASA's Office of the Chief Technologist (OCT) Game Changing Division recently funded an effort to advance a Woven TPS (WTPS) concept. WTPS is a new approach to producing TPS materials that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance by varying material composition and properties via the controlled placement of fibers within a woven structure. The resulting material can be designed to perform optimally for a wide range of entry conditions encompassing NASAs current and future mission needs. WTPS enables these optimized TPS designs to be translated precisely into mission-specific, manufactured materials that can substantially increase the efficiency, utility, and robustness of heat shield materials compared to the current state-of-the-art material options. By delivering improved heat shield performance and affordability, this technology will impact all future exploration missions, from the robotic in-situ science missions to Mars, Venus and Saturn to the next generation of human missions. WTPS can change the way NASA develops, certifies, and integrates TPS into mission life cycles - instead of being a mission constraint, TPS will become a mission enabler. It is anticipated that WTPS will have direct impact on SMD, HEOMD and OCT and will be of interest for DoD and COTS applications. This presentation will overview the WTPS concept and present some results from initial testing completed.

Feldman, Jay↗
NASA NTRS2009

NASA's Evolutionary Xenon Thruster (NEXT) Component Verification Testing

Component testing is a critical facet of the comprehensive thruster life validation strategy devised by the NASA s Evolutionary Xenon Thruster (NEXT) program. Component testing to-date has consisted of long-duration high voltage propellant isolator and high-cycle heater life validation testing. The high voltage propellant isolator, a heritage design, will be operated under different environmental condition in the NEXT ion thruster requiring verification testing. The life test of two NEXT isolators was initiated with comparable voltage and pressure conditions with a higher temperature than measured for the NEXT prototype-model thruster. To date the NEXT isolators have accumulated 18,300 h of operation. Measurements indicate a negligible increase in leakage current over the testing duration to date. NEXT 1/2 in. heaters, whose manufacturing and control processes have heritage, were selected for verification testing based upon the change in physical dimensions resulting in a higher operating voltage as well as potential differences in thermal environment. The heater fabrication processes, developed for the International Space Station (ISS) plasma contactor hollow cathode assembly, were utilized with modification of heater dimensions to accommodate a larger cathode. Cyclic testing of five 1/22 in. diameter heaters was initiated to validate these modified fabrication processes while retaining high reliability heaters. To date two of the heaters have been cycled to 10,000 cycles and suspended to preserve hardware. Three of the heaters have been cycled to failure giving a B10 life of 12,615 cycles, approximately 6,000 more cycles than the established qualification B10 life of the ISS plasma contactor heaters.

Herman, Daniel A.↗
NASA NTRS1971

Space shuttle main engine definition (phase B). Volume 2: Avionics

The advent of the space shuttle engine with its requirements for high specific impulse, long life, and low cost have dictated a combustion cycle and a closed loop control system to allow the engine components to run close to operating limits. These performance requirements, combined with the necessity for low operational costs, have placed new demands on rocket engine control, system checkout, and diagnosis technology. Based on considerations of precision environment, and compatibility with vehicle interface commands, an electronic control, makes available many functions that logically provide the information required for engine system checkout and diagnosis.

Source record↗
NASA NTRS1992

Long life Regenerative Fuel Cell technology development plan

This paper summarizes a technology roadmap for completing advanced development of a Proton Exchange Membrane (PEM) Regenerative Fuel Cell (RFC) to meet long life (20,000 hrs at 50 percent duty cycle) mobile or portable power system applications on the surface of the moon and Mars. Development of two different sized RFC power system modules is included in this plan (3 and 7.5 kWe). A conservative approach was taken which includes the development of a Ground Engineering System, Qualification Unit, and Flight Unit. This paper includes a concept description, technology assessment, development issues, development tasks, and development schedule.

Littman, Franklin D.↗
NASA NTRS2013

Woven TPS Enabling Missions Beyond Heritage Carbon Phenolic

NASAs Office of the Chief Technologist (OCT) Game Changing Division recently funded an effort to advance a Woven TPS (WTPS) concept. WTPS is a new approach to producing TPS architectures that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance. Currently, missions anticipated encountering heat fluxes in the range of 1500 4000 Wcm2 and pressures greater than 1.5 atm are limited to using fully dense Carbon Phenolic. However, fully dense carbon phenolic is only mass efficient at higher heat fluxes g(reater than 4000 Wcm2), and current mission designs suffer this mass inefficiency for lack of an alternative mid-density TPS. WTPS not only bridges this mid-density TPS gap but also offers a replacement for carbon phenolic, which itself requires a significant and costly redevelopment effort to re-establish its capability for use in the high heat flux missions recently prioritized in the NRC Decadal survey, including probe missions to Venus, Saturn and Neptune. This presentation will overview the WTPS concept and present some results from initial testing completed comparing WTPS architectures to heritage carbon phenolic.

Woven Thermal protection materials↗
NASA NTRS2013

Woven TPS Enabling Missions Beyond Heritage Carbon Phenolic

WTPS is a new approach to producing TPS architectures that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance. Currently, missions anticipated encountering heat fluxes in the range of 1500 4000 Wcm2 and pressures greater than 1.5 atm are limited to using fully dense Carbon Phenolic. However, fully dense carbon phenolic is only mass efficient at higher heat fluxes greater than 4000 Wcm2), and current mission designs suffer this mass inefficiency for lack of an alternative mid-density TPS. WTPS not only bridges this mid-density TPS gap but also offers a replacement for carbon phenolic, which itself requires a significant and costly redevelopment effort to re-establish its capability for use in the high heat flux missions recently prioritized in the NRC Decadal survey, including probe missions to Venus, Saturn and Neptune. This presentation will overview the WTPS concept and present some results from initial testing completed comparing WTPS architectures to heritage carbon phenolic.

ablators↗
NASA NTRS2000

NASA Lessons Learned from Space Lubricated Mechanisms

This document reviews the lessons learned from short-life and long life lubricated space mechanisms. A short-life lubricated mechanisms complete their life test qualification requirements after a few cycles. The mechanisms include the hinges, motors and bearings for deployment, release mechanisms, latches, release springs and support shops. Performance testing can be difficult and expensive but must be accomplished. A long-life lubricated mechanisms requires up to 5 years of life testing, or 10 to 100 years of successful flight. The long-life mechanisms include reaction wheels, momentum wheels, antenna gimbals, solar array drives, gyros and despin mechanisms. Several instances of how a mechanisms failed either in test, or in space use, and the lessons learned from these failures are reviewed. The effect of the movement away from CFC-113 cleaning solvent to ODC (Ozone-Depleting Chemical) -free is reviewed, and some of the alternatives are discussed.

Predmore, Roamer E.↗