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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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DOE OSTI2024

Sample Testing Basket: Design and Capabilities Report

SFR designs all require integral components that can withstand prolonged submersion in the liquid sodium primary coolant as well as in the gas space of the reactor vessel. Materials are often desired to withstand these conditions for the lifetime of the reactor. The Sample Testing Basket (STB) was designed and fabricated to meet the anticipated need for material exposure testing in prototypic reactor coolant environments; in the liquid sodium primary coolant and the sodium-vapor-laden gas space. Developed at Argonne National Laboratory (ANL), the STB is a piece of equipment designed for use in the Mechanisms Engineering Test Loop (METL) to allow for sodium exposure testing of materials within the METL facility.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1992

From an automated flight-test management system to a flight-test engineer's workstation

Described here are the capabilities and evolution of a flight-test engineer's workstation (called TEST PLAN) from an automated flight-test management system. The concept and capabilities of the automated flight-test management system are explored and discussed to illustrate the value of advanced system prototyping and evolutionary software development.

Duke, E. L.↗

NASA NTRS1990

Automated Platform Management System Scheduling

The Platform Management System was established to coordinate the operation of platform systems and instruments. The management functions are split between ground and space components. Since platforms are to be out of contact with the ground more than the manned base, the on-board functions are required to be more autonomous than those of the manned base. Under this concept, automated replanning and rescheduling, including on-board real-time schedule maintenance and schedule repair, are required to effectively and efficiently meet Space Station Freedom mission goals. In a FY88 study, we developed several promising alternatives for automated platform planning and scheduling. We recommended both a specific alternative and a phased approach to automated platform resource scheduling. Our recommended alternative was based upon use of exactly the same scheduling engine in both ground and space components of the platform management system. Our phased approach recommendation was based upon evolutionary development of the platform. In the past year, we developed platform scheduler requirements and implemented a rapid prototype of a baseline platform scheduler. Presently we are rehosting this platform scheduler rapid prototype and integrating the scheduler prototype into two Goddard Space Flight Center testbeds, as the ground scheduler in the Scheduling Concepts, Architectures, and Networks Testbed and as the on-board scheduler in the Platform Management System Testbed. Using these testbeds, we will investigate rescheduling issues, evaluate operational performance and enhance the platform scheduler prototype to demonstrate our evolutionary approach to automated platform scheduling. The work described in this paper was performed prior to Space Station Freedom rephasing, transfer of platform responsibility to Code E, and other recently discussed changes. We neither speculate on these changes nor attempt to predict the impact of the final decisions. As a consequence some of our work and results may be outdated when this paper is published.

Hull, Larry G.↗

NASA NTRS2006

Implementing the President's Vision: JPL and NASA's Exploration Systems Mission Directorate

As part of the NASA team the Jet Propulsion Laboratory is involved in the Exploration Systems Mission Directorate (ESMD) work to implement the President's Vision for Space exploration. In this slide presentation the roles that are assigned to the various NASA centers to implement the vision are reviewed. The plan for JPL is to use the Constellation program to advance the combination of science an Constellation program objectives. JPL's current participation is to contribute systems engineering support, Command, Control, Computing and Information (C3I) architecture, Crew Exploration Vehicle, (CEV) Thermal Protection System (TPS) project support/CEV landing assist support, Ground support systems support at JSC and KSC, Exploration Communication and Navigation System (ECANS), Flight prototypes for cabin atmosphere instruments

Industry Day↗

NASA NTRS1976

Design, fabrication and test of prototype furnace for continuous growth of wide silicon ribbon

A program having the overall objective of growing wide, thin silicon dendritic web crystals quasi-continuously from a semi-automated facility is discussed. The design considerations and fabrication of the facility as well as the test and operation phase are covered; detailed engineering drawings are included as an appendix. During the test and operation phase of the program, more than eighty growth runs and numerous thermal test runs were performed. At the conclusion of the program, 2.4 cm wide web was being grown at thicknesses of 100 to 300 micrometers. As expected, the thickness and growth rate are closely related. Solar cells made from this material were tested at NASA-Lewis and found to have conversion efficiencies comparable to devices fabricated from Czochralski material.

Duncan, C. S.↗

NASA NTRS2018

The Disruptive Technology That is Additive Construction: System Development Lessons Learned for Terrestrial and Planetary Applications

Disruptive technologies are unique in that they spawn other new technologies and applications as they grow. These activities are usually preceded by the question, "What If?" For example, "What if we could use an emerging technology and in-situ materials to promote exploration on the Moon or Mars, and then use that same technology to keep our troops out of harm's way and/or help the worlds' homeless?" This question allows us to flip the mindset of "how can people create more valuable innovation?" to "how can innovation create more valuable people?." This approach allows us to view augmented human labor as an inclusive opportunity, not a threat. The discipline of Additive Construction is growing rapidly due to the flexibility, speed, safety and logistics benefits offered as compared to standard construction techniques. Additive construction is a disruptive technology in that it employs the principles of additive manufacturing on a human habitat structure scale. Developed initially for emergency management and disaster relief applications, additive construction has now grown into military infrastructure and planetary (Moon and Mars) surface infrastructure applications as well. Additive Construction with Mobile Emplacement (ACME) is a NASA technology development project that seeks to demonstrate the feasibility of constructing shelters for human crews, and other surface infrastructure, on the Moon or Mars for a future human presence. The ACME project will allow, for the first time, the 3-dimensional printing of surface structures on planetary bodies using local materials for construction, thereby tremendously reducing launch and transportation mass and logistics. Some examples of infrastructure that could be constructed using robotic additive construction methods are landing pads, rocket engine blast protection berms, roads, dust free zones, equipment shelters, habitats and radiation shelters. Terrestrial applications include the development of surface structures using Earth-based materials for emergency response, disaster relief, general construction, and housing at all economic levels. This paper will describe the progress made by the NASA ACME project with a focus on prototypes and full scale additive construction demonstrations using both Portland cement concrete and other indigenous material mixtures. Rationale for the use of additive construction for both terrestrial and planetary applications will be explored and a thorough state-of-the-art of additive construction techniques will be presented. An evolutionary history of NASA's additive construction development efforts, dating back to 2004, will be included. The paper will then step through a series of trade studies performed to inform key processing and design decisions in the development of the full-scale ACES-3 system developed by NASA and the Jacobs Space Exploration Group for the U.S. Army Corps of Engineers (USACE) Construction Engineers Research Laboratory (CERL) in Champaign, IL. The selection of aggregate and binders, based on in-situ materials, will also be presented and discussed

Space Processing↗

DOE OSTI2018

An FPGA-Based Voltage Balancing Control for Multi-HV-IGBTs in Series Connection

The series connection of insulated gate bipolar transistors (IGBTs) allows operation at voltage levels higher than the rated voltage of one IGBT and has less power semiconductor costs compared to multilevel topologies. However, voltage unbalance during the switching transient is a challenge for series-connected device application. This paper presents an field-programmable gate array (FPGA)-based voltage balancing strategy for multiseries-connected high-voltage (HV)-IGBTs including an FPGA-based active voltage balancing control (AVBC) circuit integrated into the gate driver and the control for multiseries-connected IGBTs. As a result, the effectiveness of the control has been experimentally validated in a prototype using four 4.5 kV HV-IGBTs in series connection.

42 ENGINEERING↗

DOE OSTI2022

Reliability-Informed Economic and Energy Evaluation for Bi-Level Design for Remanufacturing: A Case Study of Transmission and Hydraulic Manifold

Abstract Design for remanufacturing (DfRem) is one attractive strategy that encourages the reuse of a product and extends the product's life cycle. Traditional design processes often only consider product reliability at an early design stage. However, from the perspective of environmental sustainability, it is becoming increasingly important to evaluate the long-term economic and environmental impacts of design decisions during early-stage design. We propose a bi-level DfRem framework consisting of system-level reusability allocation and component-level design tradeoff analysis, considering reliability and product warranty policy. First, a system-level reusability allocation problem aims at a theoretical exploration of the design space where all the components comprising the system are allocated certain reuse rates to achieve target energy savings with minimum cost. Following the theoretical exploration at the system level, a component-level analysis looks at practical design options for each component and trades-off between the overall cost and energy consumption for multiple remanufacturing cycles. Both levels of the framework require modeling component reuse for multiple remanufacturing cycles, which we achieve by using a branched power-law model that provides probabilistic scenarios of reusing the component or replacing it with a new part. We demonstrate the utility of this framework with the case study of an infinitely variable transmission (IVT) used by some agricultural machines manufactured by John Deere and show snapshots of a prototype software tool that we developed for easy use by designers.

Engineering↗

DOE OSTI2019

Production Facility Prototype Blower 1000 Hour Test Results IV

Long duration operations tests of the Aerzen GM 12.4 roots style blower in a closed loop configuration provides valuable data and lessons learned for long-term operation at the Mo-99 production facility. The blower was operated in a closed loop configuration with the flow conditions anticipated in plant operation with a Mo-100 target inline. The additional thermal energy generated from beam heating of the Mo-100 disks was not included in these tests. Twelve long duration 500 to 1000 hour tests have been completed since the first test was performed in January of 2016. All twelve long duration tests have proven successful in exposing preventable issues related to oil and helium leaks. All blower tests to this date have resulted in stable blower performance and consistency. A summary of the results for the end of the ninth test to the twelfth test is included in this report. Complete details for the previous tests are shown in the reports, Production Facility Prototype Blower 1000 Hour Test Results, II, and III.

42 ENGINEERING↗

DOE OSTI2020

Advanced Moderation Module for High-Temperature Micro-Reactor Applications

Development and deployment of micro-reactors that provide competitive efficiency, prevailing compactness, and inherent safety is an immediate focus of the U.S. nuclear industry. For thermal neutron micro-reactors operating at elevated temperature for optimized efficiency, such as micro molten-salt reactors (MSRs), heat-pipe reactors, and very-high temperature reactors (VHTRs), high-performance moderator based on metal hydride can enhance the neutron economy and therefore achieve reduced weight and enhanced portability. As unclad metal hydride inevitably decomposes at elevated temperature, an enclosure is required for hydride moderator to deliver desired performance at elevated temperatures. Conventional moderator enclosure solutions based on high-temperature alloys introduce extraneous neutron penalty into the micro-reactor, affecting the neutronic benefits provided by the hydride moderator. Additionally, the compatibility between the high-temperature alloy enclosure and the micro-reactor matrix is also a potential issue. In this report, we disclose an Advanced Moderator Module (AMM) concept enabled by an innovative enclosure solution combining the advantages of refractory metals, ceramic matrix composites (CMCs), and advanced coating technology to serve as hydrogen permeation barrier up to very-high temperatures. A schematic description of the AMM structure is illustrated in Figure A1. The AMM contains a moderating material core made of metal hydride with high thermal stability, such as YH 2-x . The hydride core is enclosed by an H 2 barrier layer coated on a ductile refractory metal liner to minimize hydrogen loss during high-temperature operation. A ceramic matrix composite (CMC) cladding is adopted to provide further structural strength, especially during power transients. Between the CMC cladding and metal liner, an extra diffusion barrier coating is inserted to suppress the chemical interaction at elevated temperatures. Hence, based on a series of innovative material solutions, the AMM is capable of containing the metal hydride core at elevated temperature (>900oC) inside coated and lined CMC envelop with negligible hydrogen loss throughout the microreactor lifetime. The benefit of the AMM technology was assessed based on a comprehensive multi-stage reactor-physics analysis. Advanced moderation based on hydride metals (such as YH2-x) enables reaching optimum moderation with higher fuel content than traditional VHTR technology, which is required to design compact micro-reactor cores targeting long-life operation. The AMM enclosure technology provides lower thermal neutron absorption rates than traditional solutions (based on stainless steel or Mo-based alloy such as TZM), which reduces the fissile enrichment requirements by 6-8% on a TRISO-fueled design based on the EMPIRE core. Finally, combining the hydride moderator with neutron transparent enclosure solutions provides significant potential to boost neutronics performance of micro-reactors in terms of increased core lifetime or reduced size and weight by 30-50% on a micro-reactor based on the Holos Quad technology. The progress and plans for on-going development and demonstration efforts are also discussed in this report. The current demonstration of AMM is focused on the hydrogen diffusion barrier demonstration under thermal cycling, while radiation tolerance demonstration is planned. The next step of the demonstration plan will be the assembly of miniature AMM for high-temperature testing, which can be used as a prototype for future pilot scale demonstration.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Development of a pixelated BaF 2 test bed for timing applications [Slides]

BaF 2 one of the fastest known scintillators, emitting at 195 & 220 nm with sub-nanosecond decay constant. Fast emission only comprises ~13% of total light. The goal is to develop a prototype BaF 2 detector system with a practical form factor and variable geometry, and characterize system performance for various timing applications.

42 ENGINEERING↗

DOE OSTI2021

Experimental Investigation of Innovative Cooling Schemes on an Additively Manufactured Engine Scale Turbine Nozzle Guide Vane

This study includes the design, validation, and fabrication via direct metal laser sintering (DMLS) of a gas turbine nozzle guide vanes (NGV) that incorporates three innovative cooling schemes specifically enabled by additive manufacturing. The novel NGV design is the culmination of an extensive research and development effort over a period of 4 years that included low- and high-speed cascade testing coupled with unsteady computational fluid dynamics for numerous candidate innovative cooling architectures. The final vane design (SJ-vane) consists of sweeping jet (SJ) film cooling holes on the suction surface (SS), sweeping jet impingement holes at the leading edge and double-wall partial length triangular pin-fin with impinging jet at the trailing edge. For comparison purposes, a second DMLS enabled vane (777-vane) was designed and fabricated with prototypical cooling circuits to serve as a baseline. This vane consists of a shaped film cooling holes on the suction surface, circular impingement holes at the leading edge, and full-length cylindrical pin-fins at the trailing edge. Experiments with the two DMLS enabled vanes were performed at the Ohio State University Turbine Reacting Flow Rig (TuRFR) at engine-relevant temperature (1375 K) and Mach number conditions. Infrared (IR) thermography was utilized to measure the wall temperature of the pressure and suction surface at several coolant mass flowrates to estimate the overall cooling effectiveness (&straightphi;). Results showed improved cooling performance for the advanced cooling schemes (sweeping jet film cooling, impingement cooling, and triangular pin-fin cooling) compared with the baseline cooling schemes.

Engineering↗

DOE OSTI2018

Hybrid graphene metasurfaces for high-speed mid-infrared light modulation and single-pixel imaging

During the past decades, major advances have been made in both the generation and detection of infrared light; however, its efficient wavefront manipulation and information processing still encounter great challenges. Efficient and fast optoelectronic modulators and spatial light modulators are required for mid-infrared imaging, sensing, security screening, communication and navigation, to name a few. However, their development remains elusive, and prevailing methods reported so far have suffered from drawbacks that significantly limit their practical applications. In this study, by leveraging graphene and metasurfaces, we demonstrate a high-performance free-space mid-infrared modulator operating at gigahertz speeds, low gate voltage and room temperature. Here, we further pixelate the hybrid graphene metasurface to form a prototype spatial light modulator for high frame rate single-pixel imaging, suggesting orders of magnitude improvement over conventional liquid crystal or micromirror-based spatial light modulators. Finally, this work opens up the possibility of exploring wavefront engineering for infrared technologies for which fast temporal and spatial modulations are indispensable.

42 ENGINEERING↗

DOE OSTI2016

FY2015 Propulsion Materials Annual Report

The Propulsion Materials Program actively supports the energy security and reduction of greenhouse emissions goals of VTO by investigating and identifying the materials properties that are most essential for continued development of cost-effective, highly efficient, and environmentally friendly next-generation heavy and light-duty powertrains. The technical approaches available to enhance propulsion systems focus on improvements in both vehicle efficiency and fuel substitution, both of which must overcome the performance limitations of the materials currently in use. Propulsion Materials Program activities work with national laboratories, industry experts, and VTO powertrain systems (e.g., Advanced Combustion Engines [ACE], Advanced Power Electronics and Electrical Machines [APEEM], and fuels) teams to develop strategies that overcome materials limitations in future powertrain performance. The technical maturity of the portfolio of funded projects ranges from basic science to subsystem prototype validation. Projects within a Propulsion Materials Program activity address materials concerns that directly impact critical technology barriers within each of the above programs, including barriers that impact fuel efficiency, thermal management, emissions reduction, improved reliability, and reduced manufacturing costs. The program engages only the barriers that result from material property limitations and represent fundamental, high-risk materials issues.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2017

Experimental Pressure Measurements on Hydropower Turbine Runners

The range of hydrodynamic operating conditions to which the turbine is exposed results in significant pressure fluctuations on both the pressure and suction sides of the blades. Understanding these dynamic pressures has a range of applications. Structurally, the resulting dynamic loads are significant in understanding the design life and maintenance schedule of the bearing, shafts and runner components. The pulsing pressures have also been seen to have a detrimental effect on the surface condition of the blades. Biologically, the pressure gradients and pressure extremes are the primary driver of barotrauma for fish passing through hydroturbines. Improvements in computational fluid dynamics (CFD) can be used to simulate such unsteady pressures in the regions of concern. High frequency model scale and prototype measurements of pressures at the blade are important in the validation of these models. Experimental characterization of pressure fields over hydroturbine blades has been demonstrated by a number of studies which using multiple pressure transducers to map the pressure contours on the runner blades. These have been performed at both model and prototype scales, often to validate computational models of the pressure and flow fields over the blades. This report provides a review of existing studies in which the blade pressure was measured in situ. The report assesses the technology for both model and prototype scale testing. The details of the primary studies in this field are reported and used to inform the types of hardware required for similar experiments based on the Ice Harbor Dam owned by the US Corps of Engineers on the Snake River, WA, USA. Such a study would be used to validate the CFD performed for the BioPA.

13 HYDRO ENERGY↗

NASA NTRS1980

Engineering test facility design definition

The Engineering Test Facility (ETF) is the major focus of the Department of Energy (DOE) Magnetohydrodynamics (MHD) Program to facilitate commercialization and to demonstrate the commercial operability of MHD/steam electric power. The ETF will be a fully integrated commercial prototype MHD power plant with a nominal output of 200 MW sub e. Performance of this plant is expected to meet or surpass existing utility standards for fuel, maintenance, and operating costs; plant availability; load following; safety; and durability. It is expected to meet all applicable environmental regulations. The current design concept conforming to the general definition, the basis for its selection, and the process which will be followed in further defining and updating the conceptual design.

Bercaw, R. W.↗

NASA NTRS1990

An expert system based software sizing tool, phase 2

A software tool was developed for predicting the size of a future computer program at an early stage in its development. The system is intended to enable a user who is not expert in Software Engineering to estimate software size in lines of source code with an accuracy similar to that of an expert, based on the program's functional specifications. The project was planned as a knowledge based system with a field prototype as the goal of Phase 2 and a commercial system planned for Phase 3. The researchers used techniques from Artificial Intelligence and knowledge from human experts and existing software from NASA's COSMIC database. They devised a classification scheme for the software specifications, and a small set of generic software components that represent complexity and apply to large classes of programs. The specifications are converted to generic components by a set of rules and the generic components are input to a nonlinear sizing function which makes the final prediction. The system developed for this project predicted code sizes from the database with a bias factor of 1.06 and a fluctuation factor of 1.77, an accuracy similar to that of human experts but without their significant optimistic bias.

Friedlander, David↗

NASA NTRS1990

Implementation of a blade element UH-60 helicopter simulation on a parallel computer architecture in real-time

A high-performance platform for development of real-time helicopter flight simulations based on a simulation development and analysis platform combining a parallel simulation development and analysis environment with a scalable multiprocessor computer system is described. Simulation functional decomposition is covered, including the sequencing and data dependency of simulation modules and simulation functional mapping to multiple processors. The multiprocessor-based implementation of a blade-element simulation of the UH-60 helicopter is presented, and a prototype developed for a TC2000 computer is generalized in order to arrive at a portable multiprocessor software architecture. It is pointed out that the proposed approach coupled with a pilot's station creates a setting in which simulation engineers, computer scientists, and pilots can work together in the design and evaluation of advanced real-time helicopter simulations.

Moxon, Bruce C.↗